Does anyone here mould plastics?

[jra61]

Hi, Does anyone here mould plastics, specifically polycarbonate? I need to mould a clear headlight lens, or can you point me in a direction.

[ventYl]

DON'T DO THAT. Unless you have ribbed reflector surface. Otherwise headlight will behave like spotlight. You'll see nothing except in small spot right in front of you and everyone arriving from opposite direction will be blinded if pointed by your headlight's beam. Even in daytime.

[jra61]

Hi, Even if I would be using one of those projectors? I read somewhere I don't want a diffused lens in-front of one of them.

[ventYl]

If you can get projector which already has surface creating proper light beam shape to not act as spotlight, you'll be probably able to source clear lens from same source too which fits the projector.

Headlight lens made from plastic is not just a simple piece of some clear plastic. It has to sustain a lot of UV for a long time (with motorcycle it is not as big concern as with car) and large amount of heat. Usually these are covered by UV protective layer but even with it a lot of older cars using plastic lens have their lens yellowish as UV degrades them.

[jra61]

Hi, Thanks for the info I thought it would be simpler and less costly than that. I guess I'll have to check around these lighting companies see if they offer a lens replacement. I'm still suprised no-one else has tried to retrofit a projector in a 1st gen before me. Even with an upgraded wiring harness the oem beam just doesn't cut-it... 

[jra61]

Just adding information I finding, This stuff ain't cheap...

MAKROLON® OP Clear & TUFFAK® Optical Grade High-Impact Polycarbonate Sheet
Polycarbonate sheet has all the properties and features you demand, including:
Virtually unbreakable with 250 times the impact strength of float glass and 30 times that of acrylic.
High optical clarity
Highest light transmission
UV stability
Low distortion