How to Make and Replace The Lense for a Dashboard Warning/indicator Light for an Antique or Classic Car

The blue lense on my classic car's dash indicator light cracked and fell out. The lights are a 1 piece unit, so no replacement lenses are available. New light units are not available through my catalog dealers. So I came up with this inexpensive, simple solution that anyone can do with simple shop tools.

Difficulty: Moderate

Instructions

Things You'll Need:

• Small drill press
• 1/2" plug cutter bit or a plug cutter the same diameter of your dash light
• 3/8" diameter dowel or equivalent(an unsharpened #2 wood pencil will work)
• Plastic driveway reflector
• plumber's putty or double stick tape
• Quick set epoxy glue
• Sanding disc
• very fine grit sand paper (220 grit)
• extra fine grit sand paper (1000 grit)
• buffer wheel or clear acrylic spray

1. 
    

   First clean around the existing hole with a small file or sand paper. Cut away any jagged edges an try to give a slight bevel around the edge of the plastic. The face of the bevel should face outward. Measure the diameter of the existing lense.

2. 
    
   cutting planks

   Obtain a driveway reflector the color of your choice. They come in Red, Blue, White and Yellow colors. Pop the lense out of the plastic holder. The lense will be in two pieces. Take one lense and stick it face(the smooth side) down on a piece of scrap wood with double stick tape or plumbers putty. Using a small drill press and the plug cutter of your choice, slowly and carefully cut several blanks. The diamond pattern on the back side of the lense will guide and help keep the cutter from slipping.

3. 
    

   Using double stick tape or plumbers putty, stick a blank on the end of the 3/8" dowel or pencil. Using a sanding disc and 220 grit sand paper, slowly bevel and shape the blank by slowly turning the dowel and sanding the edge at the desired angle. With a little practice you can even learn how to round the lense. Be sure to smooth and bevel both sides of the lense.

4. 
    

   Compare the sanded blank to the rough blank. Test fit the new lense (smooth side out) in the existing hole and fine fit by sanding. When best fit is achieved, finish sand with extremely fine sand paper ( 1000 to 2000 grit) and buff on a buffer wheel. If a buffer wheel is not available, a good finish can be achieved with multiple coats of clear acrylic spray.

5. 
    

   Mix a small amount quick set epoxy and apply some around the edge of the light hole and the inner (diamond side) edge of the lenses bevel with a tooth pick or sharp stick. When the epoxy begins to set, place the lense to fit (smooth side out) and hold in place for a few minutes.

Tips & Warnings

• The prismatic pattern on the missing lense is a circular pattern. The new lense has a diamond shaped pattern. This shows up when the lights are in use. If this will bother you, don't do this project.