I know that these things are not available for 3rd gens so i thought i might have a go at making some.I will probably get this done over the next few weeks depending on how long it takes me to pick up a light to work with.

If anyone has any great ideas or can see any possible hurdles now is the time to let me know. I would love some input now rather than post pics when i am done and get a whole lot of "shoulda, woulda, coulda"

Thanks
Damian

Are these to be a one-off or are you looking to make more & sell them?

Only thing I'd consider is keeping some colour - such as a red reflector. I think there are some laws related to this & tail lights. Home made things like this aren't going to be ADR compliant (who could afford that!) but if you do your homework and get something that's close and not obviously illegal, then the possibility of future ("not for road use") sales would be better.

Oh, and after you've made 3rd Gen tail lights and made lots of money... Don't forget us 2nd Gen wagon owners ;)

This site might give you some pointers:
http://www.alumilite.com/index.php?page=how

A major problem would be degassing, really need access to either a vacuum or pressure chamber (nothing too major, can DIY, but not "cheap cheap") to get a good result.

I looked at it a while ago, but came across the problems of ADR compliance, and associated insurance problems. And if you make them and sell them, you might possibly get into **** if someone gets rear-ended with them?

Anyway, tips... Dental plaster is a good, cheap way of making disposable moulds with excellent surface finish (which you'll need for gloss). It's like $20-30 for 20kg, from those CSR building supplies places (concrete supplies etc).

If going with urethane, you'd probably need at least a shore80A rating, probably more shore93A. Probably the minimum you could buy would be like $100 worth, but that should do maybe 5 sets of lenses.

Obtaining tint for clear urethane is nigh-on impossible. But I happen to have some, obtained as "samples". Usually you have to buy pallets of the stuff!!