Headlight foil reflector

[89AKurt]

Pet peeve of mine, why couldn't they make the back of the headlight concave, like the real thing?  This is AMT's '50 Chevy pickup, nice kit, but the flat headlight reflector is almost as lame as molded on chrome headlights.  This technique could work for those lenses with the locating pin too, after sanding off the pin (Revell 240Z for example).

1. Remove the center of the bezel.  In this case, used the Dremel; you could drill a small hole and ream out with a blade.  I kept the bezel on the tree for easier handling.
2. I used a round file to work to the bezel, leaving what I hope is enough ledge for the lens.  I also removed the remaining back locating "pin", making the edge thin as possible.
3. I scavenge things like thick shiny foil, this may have come from Christmas decorations.  Wine bottle foil could work, not the stuff with plastic on it, but real foil on more expensive wine, and that needs to be polished first.  Reynolds foil is too thin.
4. I used the drill press to make a hole the same size as the bezel, in a scrap piece of Corian.  I'm not thrilled with the rough edge, but it will not be seen.  I think using wood would be worse.
5. I put a paper towel over the foil, then pressed down with a finger and rotated back and forth.  Go just enough to create the dish, too much and foil will crease or rip.
6. Cut with scissors, very carefully to not bend the rim.  I left about a 30° tab, and folded so I could use to position using tweezers.
7. Good idea to paint silver first, on the cut bezel edge.
8. I dabbed tiny drops of superglue at 4 spots, 2 would be bare minimum.  Then I placed the foil and made sure it was centered.  After a couple of minutes, I applied more glue so it would capillary around about half that is opposite the tab.  After that was set, cut off the tab with the knife, then finished gluing.
9. I plan to use JB Weld on the back after getting the second one done, so I won't accidentally dent the foil.
10. I expect to taper the hole on the fender so they sit flush.

Just a little trick I've developed, hope this helps!

[89AKurt]

I used this same technique on my Miata (lower lights).  Difference was, a styrene tube instead of chrome bezel, and parts box lens.

[Russell C]

23 hours ago, 89AKurt said:

Pet peeve of mine, why couldn't they make the back of the headlight concave, like the real thing?  .........

My gripe as well with some kits. Got another Monogram '41 Lincoln Continental recently for a mild custom project, and one thing that always bugged me about the kit was its pie-plate flat headlight reflectors. Yours is a solution when another kit's bowl reflectors aren't readily available.

[BigTallDad]

I use a vacu-form to make the front lens and the dome-shaped backer. Now that Molotow makes those nifty chrome pens, no more BMF for the headlights.

Edited September 20, 2018 by BigTallDad

[Deathgoblin]

"googley-eyes" from craft stores work REALLY well as reflectors for round headlights.  They come in pre-set sizes so you can choose the ones that match the application.  Drill out the headlight, cut the back off the eye and dump the "pupil".  Glue it in the hole and once it's dry just chrome it with BMF or pen.