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:
Ready for production mold:
Production mold finished:
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.
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:
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.
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:
UPDATE rear view shots:
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!