DIY Broken FogLight fix. Lexan XL10.

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Search words: DIY Broken FogLight fog light glasses lenses fix. Lexan XL10.

Ok guys, everyone has broken their foglight lense. I did my reseach on clubrsx and used Lexan LX10 plastic sheet to replace the lense. Here is my instructions with pictures.

1) Take off the housing. Buy Lexan LX10 .093 thick from Home Depots ($5). Make sure you buy a BIG piece because you WILL need to make a few before cutting the perfect shape.







2) Break the OEM glass off. Dig out all the OEM sealant.



3) Trace out shape onto the plastic sheet. It won't be perfect....so test around.



4) Using an electric saw and and electric sander, cut out the pieces and perfect it's shape.







5) Fit it onto the foglights until you make one that is as fit as possible.

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6) Apply sealant.

Edit 1/23/2007: See post #144. This step can be skipped. Sealant is not required.
http://forums.clubrsx.com/showpost.p...&postcount=144





*If you mess up and wanted to clean the sealant, do NOT use Goo-off!!



7) Fit the housing back on, and allow it to dry. DONE.

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How strong is this Lexan XL10 materal?? They say this is 250 times stronger than glass! Lets put it to the test shall we?

1) BB Gun and cheap Japanese Sword test.



2) This high power BB gun can shoot through glass bottles and unopened soda cans. I've destroyed a lot of things with this BB gun, its pretty powerful.



3) Result?? Just a few dents. Not going to brake it.



4) Lets chop it with the sword.



5) A few scratches. Not going to break it.



6) Try bending this shit?



I don't think the rocks on the road can break this too easily. I'll see if this will last me 10,000 miles. At least it's stronger than the OEM glass.

Total cost: $10.
Total time: About 4 hours.

[joriz RSX]

nice DIY even though i dont have foglights

lol @ shootin it up with the BB gun

[Darqnez]

good job vince!!!!!!!!!!

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Trust me, I TRIED to break that shit. Not easy man. People use this for house security, you just CAN'T break it (within reasonable force).

Oh yeah, I have one more set for sale $30 SHIPPED. PM me. I cut out an extra set. Fits perfectly! Will save you at least 4 hours for work.

[Nate2k3]

Funny. Shooting it up with a BB gun shows the fix's durability. If the sealant doesn't melt in the long run then u got yourself manmade "oil." Get ready to pattent this fix. I want to get fogs but all I know is the laminx fix, but your's definitely looks better and cost effective. Time consuming is the down side. Are there other lexan colors available.

[mojorizin]

Lexan is STRONG. I trust my safety to it daily. I'm writing this from a locked psych ward in a state hospital. The nurses station windows are lexan. I've seen a 300+ lb man try and break these out with a chair. Thats a lot scarier than finding a broken foglight. The lexan owned him!

I'll TAKE those lenses off your hands CIA....

[RSX-CT]

One little word of advice lexan will yellow over time with exposure to UV. You need to use only UV coated Lexan like the stuff he used, otherwise you will be sorry. Halogen bulbs do put out UV, so you may need double sided UV coated polycarbonate.

[JoePa]

Originally Posted by RSX-CT

One little word of advice lexan will yellow over time with exposure to UV. You need to use only UV coated Lexan like the stuff he used, otherwise you will be sorry. Halogen bulbs do put out UV, so you may need double sided UV coated polycarbonate.

yeah that....if it was indeed better than the oem glass, for that much cheaper, honda would have used it...CIA, great fix, but I fear over time it will not look as nice as it does now
in for pics in a year

[lombard0]

One more thing; how will this stand up to the temperature of the bulbs? I wonder if it will discolor or melt.

How long have you had them in use with the new lenses?

Check out this post too; seems like others have tried the Home Depot Lexan. http://forums.clubrsx.com/showthread...ight=fog+lexan

I'm thinking we need to MR10 instead of LX10.

[aziatiklover]

very nice man

[stardotstar]

Sounds like a great cheap fix for the mean time.

[Konsept]

holy shit... *file: Save-As*

How long would say it takes for the adhesive to fully dry?

[RSX-CT]

Almost all headlamps are currently made with double sided UV protected polycarbonate. You can find some newer lenses in the junkyards and cut those up to make the same thing. As a matter of fact, I have used TSX lenses to make foglight lenses before.
Polycarb, depending on grade, homopoly vs. copoly, brand etc. can vary in maximum continuous air temperature. Typically this value hovers around 475F and a temperature of delfection around 550F, so nothing to worry about!

[rly44]

I did this fix and after a few days I got some bubbles forming in the Lexan lense,. Not to mentions they warped just a little bit. I used XL10 in case anyone is wondering. Has anyone tried any other materials?

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Oh really?? I'll need to use it for a few days and I'll report back.

But the description says it stand up to 900F degrees of heat (or 400C degrees).

I will report back.

[S1_Ikon]

looks sturdy .... might give it t try

[rly44]

Oh.. BTW.. My lenses bubbled while using the Yellow NOKYA bulbs.. Im not sure if the stock bulbs did it or not though.

[integra_dc2]

Hi Guys,
I repaired my fog light lenses with vinyl from Canadian Tires.. i donno if u guys have Canadian Tires in the States.

But they are just regular transparent vinyl that is about .5mm thick... and it works like a charm..

I have replaced it for almost 5 months and also I have HID as my foglights.. those vinyl tends to hold up pretty well without any discoloring or turning yellowish.


the way i did it is much easier than this guy is doing, i simply cut a square shape and have the entire sheet cover it up from the black plastic around the foglight housing.

so i didn't cut it into oval, then glue it.

but it holds extremely tight already. for all the lazier ppl out there, this is another easy method to repair your fog lenses.

[RSX-CT]

This XL10 sheet is meant specifically for skylight fixtures. It is probably a polycarbonate mixed with another plastic, and internally lubricated. That would explain why it could bubble under heat. You need polycarb only sheeting, which homedepot and such are not going to carry.

[j0sh]

ya after i did this with my foglights like 6 months ago i had them on in the summer i got a few bubbles but it is still much better than the cracked oem stuff.

[rly44]

Originally Posted by RSX-CT

This XL10 sheet is meant specifically for skylight fixtures. It is probably a polycarbonate mixed with another plastic, and internally lubricated. That would explain why it could bubble under heat. You need polycarb only sheeting, which homedepot and such are not going to carry.

I have some old crap civic halo projector headlights that are pretty much garbage lying around. Do you think if I cut out some lenses in those that the material would hold up better than the Lexan XL10?

[RSX-CT]

Originally Posted by rly44

I have some old crap civic halo projector headlights that are pretty much garbage lying around. Do you think if I cut out some lenses in those that the material would hold up better than the Lexan XL10?

Yes, those should work fine

[ClA]

Originally Posted by integra_dc2

the way i did it is much easier than this guy is doing, i simply cut a square shape and have the entire sheet cover it up from the black plastic around the foglight housing.

so i didn't cut it into oval, then glue it.

but it holds extremely tight already. for all the lazier ppl out there, this is another easy method to repair your fog lenses.

Got pictures? Because I have no idea what you are talking about.