Need some help/oppinions!

[Hot_Wheels]

so lately ive been trying to figure out how to make clear headlight lenses so that we can use HID head lights with out haveing the refractors in the glass. i bought a kit to make molds for pouring plastic. im trying to make the die for the mold using a stock lens but im running into some problems. first off is there are 3 nubs on the outside. i tried sanding them down and got pretty close but nothing smooth. i was using a grinder to bring the nubs down and then hand sanding but it is taking forever!!! second problem is when i do the casting for the inside of the headlight i need to get rid of the refractors. we tried filling it with bondo which its getting is smooth but im affraid then when casting the mold that the bondo will be to pourous and not come out clear in the plastic. i was thinking of painting the bondo with a high gloss paint to seal it up and make it less porousable? in this whole process in sanding one lens already broke so its being glued back together and hopefully will come out seamless. if anyone has any better ideas on how to make clear lenses or sanding glass tips please let me know! im wondering if i just use the light i have make a rough cast with the plastic. and then tweak and sand the plastic which i think would be easier then sanding the glass and make yet another mold but that would be 4 molds all together and alot of money...

[big_ty2003]

good luck my friend, hope you get it figured out. I think as you said making the plastic mold first then smoothing it out would be easiest.

[rallytiva71]

Hey Ricky,Just Paint the Surface of the Bondo With 3-4 Coats of rustoilum Paint,They have the Professional grade fast driying Sprays at Menards for about $6 a piece , you probably only need 2,That will make the surface nice & smooth, or Use Marine Gel Coat, The have it at any Marine Shop, Boat US in Lombard it's close by, Make sure you let it dry for at least -4-5 days,Good Luck Bro!