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has anybody made nice headlight covers?

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Old Jul 17, 2012 | 03:22 PM
  #1  
Z28Johnny's Avatar
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has anybody made nice headlight covers?

I have found some online for like $60. I used to have some when I first got my IROC 18 years ago, but one fell off long ago. It seems like you would be able to buy some 1/8" plexi glass from HD, tint the back side of it with window tint and come up with a pretty simple way to attach them. I'm thinking if I could make a nice set for $15 that I would want to go that route.

Has anybody successfully made their own? Pictures, directions, advise...

Thank you,
John
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Old Jul 17, 2012 | 07:56 PM
  #2  
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From: 51°N 114°W, 3500'
Car: 87 IROC L98
Engine: 588 Alcohol BBC
Transmission: Powerglide
Axle/Gears: Ford 9"/31 spline spool/4.86
Re: has anybody made nice headlight covers?

I don't think I have any "good" pictures but here's mine.

3/16" Lexan. I attached some thin aluminum angle on both sides of the opening and installed Dzus springs in the aluminum. I used some posterboard to make templates then cut out the Lexan with a jigsaw. I painted the edges black to hide the aluminum brackets and just use 4 Dzus fasteners to hold them on.

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Old Jul 17, 2012 | 09:28 PM
  #3  
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Re: has anybody made nice headlight covers?

Do you have any pictures of your aluminum angle with the fasteners? I think yours look really cool. "Tuff" looking!

I'm pricing the aluminum angle at $5, lexan at $20, plus tint, plus fasteners. I might just order some... About how much do you figure you spent on yours?
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Old Jul 17, 2012 | 10:40 PM
  #4  
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From: Utah
Car: 89 RS 89 iroc 87 firebird
Engine: 3.1 Turbo/ 355 twin turbo
Transmission: a4 w/ 4500 stall/ a4 / t5
Axle/Gears: strange s60 /w 3:42's
Re: has anybody made nice headlight covers?

+1 i thought about doing the same thing.
how did u attach the aluminim angle to the sides , knowing how fast ur car is and they dont come off i think is should do the same seeing as how i will be land speed racing my car
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Old Jul 17, 2012 | 10:58 PM
  #5  
AlkyIROC's Avatar
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From: 51°N 114°W, 3500'
Car: 87 IROC L98
Engine: 588 Alcohol BBC
Transmission: Powerglide
Axle/Gears: Ford 9"/31 spline spool/4.86
Re: has anybody made nice headlight covers?

Just some 1" aluminum from Home Depot. It's machine screwed to the opening walls. The fasteners are Dzus springs pop riveted to the aluminum with a hole through the aluminum for the Dzus fastener to go through.

A Dzus like this
http://www.jegs.com/i/JEGS+Performan...82201/10002/-1

Into a spring like this
http://www.jegs.com/i/JEGS+Performan...82256/10002/-1
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Old Jul 17, 2012 | 11:05 PM
  #6  
AlkyIROC's Avatar
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From: 51°N 114°W, 3500'
Car: 87 IROC L98
Engine: 588 Alcohol BBC
Transmission: Powerglide
Axle/Gears: Ford 9"/31 spline spool/4.86
Re: has anybody made nice headlight covers?

I looked on all my SD cards and couldn't find any other pictures showing details. I'll try to take a couple before the weekend.

Also try using the search feature. The question has been asked many times.
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Old Jul 17, 2012 | 11:32 PM
  #7  
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From: Utah
Car: 89 RS 89 iroc 87 firebird
Engine: 3.1 Turbo/ 355 twin turbo
Transmission: a4 w/ 4500 stall/ a4 / t5
Axle/Gears: strange s60 /w 3:42's
Re: has anybody made nice headlight covers?

so u just drilled holes and basically bolted them there.
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Old Jul 18, 2012 | 07:15 AM
  #8  
AlkyIROC's Avatar
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From: 51°N 114°W, 3500'
Car: 87 IROC L98
Engine: 588 Alcohol BBC
Transmission: Powerglide
Axle/Gears: Ford 9"/31 spline spool/4.86
Re: has anybody made nice headlight covers?

In simplest terms, yes. The sides of the headlight openings are not perfectly straight so some slight modifications are required to get the aluminum in the position that I wanted. Since I have no requirement for needing the covers removed and keeping it looking pretty, the aluminum is bolted on. The cover itself can be removed for cleaning or headlight access by taking off the Dzus fasteners
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Old Sep 23, 2012 | 10:14 PM
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From: Eastern NC
Car: 85 sport coupe
Engine: 355 sbc
Transmission: 700R4
Axle/Gears: soon 4th gen 3.23 w/ Posi
Re: has anybody made nice headlight covers?

so would anyone be considering making and selling some. I've always wanted some clear ones but don't wanna get the ones like GTS where all they do is use double sided tape to hald them in.
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Old Sep 24, 2012 | 08:10 PM
  #10  
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From: Wesley Chapel, Florida
Car: 1991 Camaro Z28
Engine: Dart SHP 406ci T88 turbo
Transmission: T56
Axle/Gears: QP 35 spline Ford 9" 3.50 gears
Re: has anybody made nice headlight covers?

Here are some that I made similar to Alky's but 1/4" turn fasteners on the top and bottom

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Last edited by pwdbychevy; Sep 24, 2012 at 08:15 PM.
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Old Sep 24, 2012 | 09:25 PM
  #11  
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From: Eastern NC
Car: 85 sport coupe
Engine: 355 sbc
Transmission: 700R4
Axle/Gears: soon 4th gen 3.23 w/ Posi
Re: has anybody made nice headlight covers?

pwdbychevy, would you be willing or able to make another set that I could buy from you. I like your setup just as much.
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Old Sep 25, 2012 | 04:54 AM
  #12  
novaderrik's Avatar
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From: Howard Lake, MN
Car: 86 Camaro
Engine: 355- hopefully a 5.3 this summer
Transmission: 700r4
Axle/Gears: 3.42
Re: has anybody made nice headlight covers?

i made some a couple of weekends ago.. got some .080 lexan (3/16" is just overkill..).. also picked up some self tapping screws and a stick of 1/2" x 1/2" x .125 aluminum angle.. i made a poster board template and cut the lexan with a sharp utility knife, for mounting brackets, i cut the aluminum angle into 3/4" long chunks and used the self tapping screws to hold the brackets to the nose and the lexan covers to the angle.. then being the "Joe Dirt" clone that i am, i used black duck tape to cover up the seams and screws..
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Old Sep 25, 2012 | 05:11 AM
  #13  
pwdbychevy's Avatar
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Joined: Aug 2001
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From: Wesley Chapel, Florida
Car: 1991 Camaro Z28
Engine: Dart SHP 406ci T88 turbo
Transmission: T56
Axle/Gears: QP 35 spline Ford 9" 3.50 gears
Re: has anybody made nice headlight covers?

Originally Posted by NCcowboy
pwdbychevy, would you be willing or able to make another set that I could buy from you. I like your setup just as much.
I would make you some but I sold the equipment I used to make them. I used to sell kits here on thirdgen but stopped making them. Took too much of my time.
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Old Sep 26, 2012 | 12:00 AM
  #14  
oil pan 4's Avatar
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From: High plains of NM
Car: 89 Firebird
Engine: L98
Transmission: T-56
Axle/Gears: 3.73
Re: has anybody made nice headlight covers?

Those are very nice, wow.
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Old Sep 26, 2012 | 01:36 AM
  #15  
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From: Lynden WA
Car: 84 Trans Am, 84 Fiero, 86 944
Engine: 5.0, 2.5, 2.5
Transmission: 5spd
Re: has anybody made nice headlight covers?

Originally Posted by NCcowboy
so would anyone be considering making and selling some. I've always wanted some clear ones but don't wanna get the ones like GTS where all they do is use double sided tape to hald them in.
i got the gts ones recently and while they do recommend using just the 3m adhesive on the brackets, they do come with screws to permanently mount both the brackets to the car, and the covers to the brackets

also i am very happy with how they look

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Old Sep 26, 2012 | 05:15 AM
  #16  
pwdbychevy's Avatar
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From: Wesley Chapel, Florida
Car: 1991 Camaro Z28
Engine: Dart SHP 406ci T88 turbo
Transmission: T56
Axle/Gears: QP 35 spline Ford 9" 3.50 gears
Re: has anybody made nice headlight covers?

Originally Posted by kmcn47
i got the gts ones recently and while they do recommend using just the 3m adhesive on the brackets, they do come with screws to permanently mount both the brackets to the car, and the covers to the brackets

also i am very happy with how they look



What causes these covers to pop off at high speed is air rushing up under the cover and pushing it out from the back side. You can screw the brackets in but the cover will still come off unless you somehow bolt the cover to the bracket. Thats why I came up with my design. I've driven the car over 150mph in my test grounds in rural mexico and the covers are rock solid. In my garage I had 4 sets of right side gts covers from my times in Germany on the autobahn.
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Old Sep 26, 2012 | 03:22 PM
  #17  
kmcn47's Avatar
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From: Lynden WA
Car: 84 Trans Am, 84 Fiero, 86 944
Engine: 5.0, 2.5, 2.5
Transmission: 5spd
Re: has anybody made nice headlight covers?

well, mine are sealed pretty good to the bottom of the headlight pocket, and there isn't a gap between my hood and bumper so idk where airs gonna get in behind em at, theres no gap because my car got backed into and pushed the bumper up, did 95 last night after putting them on yesterday, they stayed on, and it was pouring rain all day today doin 65-70 on the way to school, still on there, i have to admit i was terrified that they'd blow off and be gone in a day but there on there pretty good
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Old Oct 3, 2012 | 05:57 PM
  #18  
kmcn47's Avatar
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From: Lynden WA
Car: 84 Trans Am, 84 Fiero, 86 944
Engine: 5.0, 2.5, 2.5
Transmission: 5spd
Re: has anybody made nice headlight covers?

sure enough i go and say that, the day before i planned to screw the covers to the brackets and the brackets to the car with the supplied screws, lost em both today, only found the passenger side, anyone got a drivers side one? how much shipped to 43912 has to be clear , also **** these clips i'm gonna get small l brackets from lowes and just use the screws if they were somehow secured better then the stupid little clip in design they'd of been fine
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