3rd Brake Light *Low Profile Carbon Fiber (OMG CARBON) (GB OVER- see link)
 

GB is finished! A while ago actually... But this thread is still going with info. I am now making them for sale in a new thread:

http://www.ft86club.com/forums/showthread.php?t=87886

Here' is my attempt at a 3rd brake light mod, full carbon fiber. Tooling and fabrication are on the professional level (some of you already know I do composite aircraft repair/modification), and final parts turned out just a little better than I expected. I used the 18" LED bar and wiring extensions from www.superbrightLEDs.com and the rest is sourced from my workplace. I was influenced by the final product of this thread but wanted easier fabrication, and was also influenced by this thread but wanted a better final product. So I sort of combined the ideas and made my own. I wanted something very low profile, enough that it couldn't be seen in the rear view at all. The final version is slightly visible in the mirror, but only a very, very thin sliver. Please note, the gray tape is temporary. I am working with our 3M Rep to try out some black tapes to make it more invisible. I only have factory tint, so, almost none.

Anyways, let me know what you think. If there's enough interest I can fabricate more and sell them as-is (carbon shroud only), or ideally as kits with instructions and everything included.

Here is the tooling for the master forms and the final mold.

In process:
http://i11.photobucket.com/albums/a1...ps91390ecd.jpg

Ready for production mold:
http://i11.photobucket.com/albums/a1...ps4279c238.jpg

Production mold finished:
http://i11.photobucket.com/albums/a1...psa73ea024.jpg

http://i11.photobucket.com/albums/a1...ps0a3d988c.jpg

First layup under vacuum. The spots are excess resin that are being squeezed from the part through the release film. The vacuum bag comprises four layers, peel ply, release film, breather/bleeder, and vacuum bag. The benefit to vacuum bagging is much better part integrity, the layers are compacted together to make the part as light and strong as possible. The only next step would be an autoclave, but that's WAY beyond the scope of this part... As-is, it's made of three layers, 0°, 45°, and 0° orientation using plain weave 3K fabric, BMS9-8, Boeing spec. The shroud weighs almost nothing when it's finished. Aircraft grade.
http://i11.photobucket.com/albums/a1...psd33fc471.jpg

I wanted the skin facing the interior of the car to have the nice carbon finish, this image explains why. The bag-side is less attractive, and through even untinted glass it can barely be seen. The bag side also gets painted with matte black Plasti-Dip to protect from UV and eliminate any possible glossiness.

Final part after trim and cleanup:
http://i11.photobucket.com/albums/a1...ps54c615e9.jpg

http://i11.photobucket.com/albums/a1...psf28e7ed0.jpg

Ready for install. I am using felt across the top edge because I want it to gently wedge under the head liner, I left gaps to ensure air could still circulate.
http://i11.photobucket.com/albums/a1...ps0fd8e38c.jpg

PLEASE NOTE: The gray tape is temporary. I'm working with our 3M rep to test out some black tapes that are also UV resistant. I want this shroud to be hardly visible at all.

First installation and test fit:
http://i11.photobucket.com/albums/a1...pscaa39f93.jpg

http://i11.photobucket.com/albums/a1...psc4e3ddec.jpg

UPDATE rear view shots:
http://i11.photobucket.com/albums/a1...sa0af550b.jpeg

http://i11.photobucket.com/albums/a1...s3615500e.jpeg

I will post updates when I get the new black tape and try a couple ideas to ease final fitment and make it almost idiot proof to keep it square.

Again if there's enough interest, I can make more. I love how it turned out. Thanks for checking it out!

Final design! I have measurements for final trim dimensions using black 3M 4949 1/4" wide tape and will include it in the production mold ASAP to ensure consistency and speedy fabrication.

Request:
I would like to send a sample piece to someone who is a tint guru and could test it for me on a piece of test glass left in the sun for a few days. I will include a small piece of carbon, sprayed with black Plastidip exactly like the production piece to mimic similar conditions.

Please note: the smudging on the carbon shroud surface in the pic below is from me handling it after removal and not cleaning it thoroughly...

http://i11.photobucket.com/albums/a1...ps249b33c1.jpg

@ck-GT86

Would you be willing to sell these?

I love this!

Absolutely, I need to calculate time and materials, anything laid up by hand can be time intensive. I'll look into my costs and see what's reasonable if I were to make one or two vs 20 or more. Maybe a group buy if enough people can commit.

Id be interested. How much are you thinking

That turned out really nice!

Interested in a group buy as well.

Interested if the price is right.

that looks badass. clean too. unfortunately, the cost it'll require for you to produce a bunch probably won't be worth for many to spend on that mod... but who knows. either way, that's a clean looking custom mod!

whoa! Looks great!

+1 for additional fabrication. Very nice.

Very nice!

Have you, by chance tried putting some low frequencies through it to see if it rattles? One of the main reasons I did my own version of this install was because the stock light rattle against the glass very heavily after I installed a sub.

Cheers

Yes, aint no thang. I have two JL 8W3v3 and they don't hit quite hard enough to cavitate the cabin and crack the windshield, but the light shroud is solid, no noise whatsoever. I specifically wanted to avoid rattles, so the LED bar mounts to the forward-most face of the carbon that butts against the head liner, which has a slight curve that's not very apparent from the photos. This curve adds a slight preload and keeps it from rattling. It sits about 1/4" off the bottom face (large surface) and from the glass, so there's no chance for rattle.

Simply perfection! ;-)

I love this. I would buy it if the price is reasonable

in if price is right.. :)
would also like a non cf version, but either way.. in if price is right

Great work OP, looks first class!
Also, was there a reason for not going with clear 3m tape and trying to source black instead? Just curious..

Awesome fabrication wheelhaus.
The fit and finish look great!

Looking forward to seeing the end result with the 3m tape.

I might have to jump on this list get one if you do eventually plan to make a batch of them.

FWIW, wheelhaus has made me custom parts in the past. He's a good friend and very talented in designing and manufacturing of these things. He has great attention to detail. I saw his prototype for this last night. You won't be disappointed.

Thanks! Do you mean non carbon, as in fiberglass? We have some resin dye that can make fiberglass appear black. That's certainly possible, might save a few bucks on materials. I have a feeling that this won't be prohibitively expensive. It won't be $50, but certainly won't be $500 either. If you're referring to formed plastic, I'll look into it, but that will take time. Making some decent quality tooling on a budget is the biggest hurdle, I don't want to use/sell something made from plywood, duct tape, and hot glue, but can't afford exotic stainless steel tooling, either.

The clear 3M tape is an option, but I want to avoid having the red light bleed anywhere. The clear might act as a lens and could capture/prism some of the light, which would appear to glow on its own. That's the same reason I want a matte black finish inside the shroud.

Thanks for satisfying my curiosities!
Again, finished product looks beautiful in every way!!

Dyed fiberglass would be fine for my needs personally, but I'd be in for either option, if enough interest is generated to warrant you doing a run of them in the future..



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I need it in carbon for the added weight reduction.

.

This looks awesome! I was happily surprised with how low profile the light was that you mentioned in the second link you posted. How much thickness were you able to decrease your version by?

I'd be in for a group buy. That looks great!


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in for the group buy. Looks great!

Updated first post with these pics. Its pretty low. I believe the edge that meets the headliner is close to being flush, but the most limiting factor is the trailing edge. If its too high and COMPLETELY invisible from the rear view, then it cuts off too much of the light path, and mounting the LED bar higher isn't really an option. So the most visible edge is the very last trailing edge because it's the lowest and farthest point from the top of the rear glass. That's the faint curve you see.

http://i11.photobucket.com/albums/a1...sa0af550b.jpeg

http://i11.photobucket.com/albums/a1...s3615500e.jpeg

This looks awesome - nice work!

I'm quite interested in getting one of these if you do a production run. :D

Looks sweet. Make sure to price it right, though. Someone posted the same solution for a mustang that worked beautifully for me, and it was very reasonably priced.

Also note: If you've got anything under 20% tint on rear window, you really won't be able to see the gray tape at all

Even though it already ordered the one for a mustang if you sell this and priced I will definitely be in for buying one.

Goodness gracious.

i like it. if there is a group buy, please let me know.

Is your rear deck fully/properly reinstalled? Maybe it's just the pic, but it looks bowed up in the center, which is an issue I had and described in my 3rd brake light thread. It's an easy fix...you have to make sure the plastic under the stock 3rd brake light pokes into and hooks on the metal above the trunk. Just something to check! Again, maybe it's just the pic.

I'm in support of a group buy.

Also, simply, nice work.

interested in a group buy if the price is right.

Interested

Count me in for a group buy.

Thanks for all the feedback guys, I'll let you all know as soon as I am ready to start fabrication. BTW I just fixed the pics in the first post, some pics were missing.

I think you're right. After removing the OEM brake light I glued the hook piece back into place, but I think I missed latching into position because it was getting kinda late and I was a little derpy.
:bonk:

I definitely want one of these, preferably in a less expensive fiberglass. I think it would also be nice to make a matching triangular piece to cover the wound left on the back dash after removing the factory light. I was going to make one myself from plastic, but I think it would be smart to pair these items for sale.

I Prefer CF but would be happy either way.
It looks like you have a lot of interest wheelhaus. I hope we follow through.