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DIY: Fiberglass Eyelids

Discussion in 'General Tundra Discussion' started by boardude, Aug 7, 2016.

  1. Aug 7, 2016 at 3:42 PM
    #1
    boardude

    boardude [OP] I am Batman!

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    I couldn't really find anyone who made eyelids for the 2014+ Tundras and I didn't want to slap a vinyl on the headlight so I just made my own fiberglass eyelids. Below are the steps that I took to make these. But first the fine print....

    Disclaimer: As any DIY, this thread is not telling you how to make perfect fiberglass eyelids rather I am just sharing how I made mine. If you attempt the mod and f*ck up something I am not responsible for anything.

    And now to the DIY. Feel free to PM me if you have any questions or need any help. The resulting product below was actually my second attempt so many lessons learned lol.

    The tools and products I used were:
    - Beer
    - 3M Painters Tape
    - Mold Release Agent
    - Fiberglass cloth and resin
    - Beer
    - Mixing stick
    - Bondo glaze and filler
    - 3M double sided tape
    - Several cheap paint brushes (you will most likely toss these when you are done). Not too cheap where the bristles pull. Otherwise you will be picking these out of the resin lol
    - Flat head screw driver
    - 10mm socket wrench/ratchet
    - Beer
    - Patience
    - lacquer thinner
    - Gloves if you don't want sticky hands for 2 days
    - Beer
    - Rattle can primer (your choice)
    - Final paint and clear coat. I used color match from automotivetouchup.com


    [​IMG]



    First I removed the grill and panels under the headlights then removed the three bolts for each headlight and pulled them out.

    [​IMG]

    I cleaned and taped off the entire front of the headlight with 3M painters tape
    [​IMG]

    Next I took a sharpie and outlined the shape of the eyelid I wanted. This outline was not intended to be the final shape but more to make sure that I cover the entire area with resin.
    [​IMG]

    I made sure the entire area within the outline was completely smooth with no creases or folds in the tape because the cloth will inherit all of these when the resin is applied and dried which means more work in the end sanding these out.
    [​IMG]

    Applied the mold release agent on the headlights in the outlined area and a couple inches past that as well.
    [​IMG]

    I cut 4 pieces of fiberglass cloth (2 for each side) large enough to cover the outlined area.
    [​IMG]

    About 15 mins after applying the mold release agent I mixed up a batch of resin. I only mixed enough to apply the first cloth on both headlights. Then I began to brush the resin on the cloths starting from the middle and working my way out to the edges. I used my outline as a guide to know where to apply.
    [​IMG]

    After 5 mins of the first cloth I mixed another small batch of resin and applied the second cloth using the same method. I smoothed out all air bubbles and made sure there was no separation between the two cloths. After another 5 mins I made a third batch of resin and caked it on. I did this to make them more solid and also when they cure and it comes time for sanding, its easier to sand and smooth the resin then the actual fiberglass.
    [​IMG]

    Gave it about 3 hours to dry and they were ready to be removed. I took a sharpie and traced the outline on the fiberglass as a guide to wear to cut.

    I slowly used a flat head and started to peel the edges of the eyelids off the headlights. Once the edges were clear I stuck the entire flat head down the middle and the whole thing popped right off.
    [​IMG]

    I cut the excess cloth off and used a dremel to cut close to my outline. Then I started sizing up the eyelid on the headlight to determine where to cut for my final shape. I did this in small sections of cutting then sanding.
    [​IMG]

    This was the most time consuming part as its easy to make a wrong cut. Plus I am super anal about everything having to be level and lined up so I might have gone overkill on a few spots lol. But in the end I think it paid off:
    [​IMG]

    Once I had the final shape I hit it with 150 grit, then 220 and then 400 sandpaper. I sprayed a few coats of white primer on the eyelids:
    [​IMG]

    After a few hours I then hit them again with 220 paper. This was to reveal the high and low spots of the fiberglass. The white patches were the low spots which some were filled with the primer. For the spots that need more filler I marked with a sharpie and then used bondo glaze and filler. Once the filler was dry 20 mins later I hit it with 400 to smooth the filler and repeated where necessary
    [​IMG]

    Once I was happy with the shape and smoothness I hit it with several coats of primer, wet sanded with 400 paper, applied the color matching paint and clear coats:
    [​IMG]

    Used 3M double sided tape to secure to the headlights and..... Whammy!!
    [​IMG]

    [​IMG]
     
  2. Aug 7, 2016 at 3:49 PM
    #2
    Sean266

    Sean266 #ThinBlueLine Staff Member

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    Nicely done man!! Added to the DIY sticky.
     
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  3. Aug 7, 2016 at 3:51 PM
    #3
    mudsweatngearz

    mudsweatngearz New Member

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    Wow! great write up. You are very talented. Is there a practical use for doing this or is it for looks? Still trying to decide if I like it looks wise, could grow on me.

    Practically it may help keep UV clouding at bay some.
     
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  4. Aug 7, 2016 at 4:09 PM
    #4
    boardude

    boardude [OP] I am Batman!

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    Thank you sir! It's all for looks really. I really liked them on my Taco and wanted some for the Tundra. I like the way the eyelids follow the contours of the fender and grill
     
  5. Aug 7, 2016 at 4:10 PM
    #5
    mudsweatngearz

    mudsweatngearz New Member

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    Window tint
    I will say you really do live up to your screen name tho.....LMAO
     
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  6. Aug 7, 2016 at 4:17 PM
    #6
    Bob

    Bob Member Staff Member

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    Nicely done, came out great

    (And good work on that detailed write up)
     
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  7. Aug 7, 2016 at 4:20 PM
    #7
    TNTundra08

    TNTundra08 New Member

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    What kind of beer works the best for this project? Lol
     
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  8. Aug 7, 2016 at 4:36 PM
    #8
    boardude

    boardude [OP] I am Batman!

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    Gracias!

    I started with a couple blondes during the fiberglass and resin stage but quickly moved to IPAs when I got to the shaping and sanding part lol.
     
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  9. Aug 7, 2016 at 4:40 PM
    #9
    frogger

    frogger #teamjapotruck

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    Nice work...looks great
     
  10. Aug 7, 2016 at 6:56 PM
    #10
    RowdyRon

    RowdyRon Not too old to play

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    Great write-up! Very nice job!
     
  11. Aug 7, 2016 at 7:03 PM
    #11
    MotoTundra

    MotoTundra Adrenaline Addict

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    They look great! I have always wanted to try to mess with fiberglass, maybe someday I will give it a try.

    Great write up. Thanks for sharing.

    I dare you to make some color matched fiberglass fillers for your front bumper......

    Double dog!
     
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  12. Aug 7, 2016 at 7:35 PM
    #12
    boardude

    boardude [OP] I am Batman!

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    You had to pull the double dog lol! That kinda fiberglass work might be out of my skill set, but I like where you are going with this.. now you have me thinking of my next potential mod!
     
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  13. Aug 7, 2016 at 8:36 PM
    #13
    MotoTundra

    MotoTundra Adrenaline Addict

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    Haha I'm not familiar with fiberglass construction but if it's possible l really think it would look sick! Definitely one of a kind! I love that bumper and also like when mesh or diamond plate fills those gaps, but something color matched and shiny, oh sh*t!!!
     
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  14. Aug 7, 2016 at 9:08 PM
    #14
    matluth

    matluth Fish On!

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    Well done. :thumbsup::thumbsup::thumbsup:. By the way, Dechutes IPA (Oregon) is great. Oregon grows the best hops in N/A. Not my humble opinion. Fact.
     
  15. Aug 7, 2016 at 11:42 PM
    #15
    TRON

    TRON The Game Has Changed

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    :cheers: :drool: Looks so good! I gotta check these out soon!!
     
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  16. Aug 8, 2016 at 4:44 AM
    #16
    ColoradoTJ

    ColoradoTJ I'm a boob guy.

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    I'm a little confused on the part list requirements. I see you have beer listed 3 times. Was that a misprint or just a needed requirement? Can I just get the beer all at once or should I go to 3 different liquor stores? Can one substitute whiskey or will this project come out crazy?

    Little help here.....





    :D:thumbsup:


    Looks great IMO, how many hours do you think are invested in your project?

    Better yet, probably should measure this project by six packs.

    Well done.
     
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  17. Aug 8, 2016 at 4:46 AM
    #17
    RowdyRon

    RowdyRon Not too old to play

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    Used to drink a lot of Henry Weinhard beer when I lived in Oregon. Would load up my chest waders with it when fly fishing - its a wonder I didn't drown.
     
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  18. Aug 8, 2016 at 10:12 AM
    #18
    boardude

    boardude [OP] I am Batman!

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    One of my favorite IPAs - I don't doubt that fact at all. The truth is in the taste!
     
  19. Aug 8, 2016 at 10:25 AM
    #19
    boardude

    boardude [OP] I am Batman!

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    Haha originally I had beer listed more in the parts list but didn't want anyone to think the main purpose of the project was to get drunk. This DIY is from my second attempt at this. Lets just say that bourbon was a variable factor during my first attempt lol.

    Not including curing and drying times I probably spent 3-4 hours with the shaping and sanding taking the majority of the time. I am pretty anal on things being perfect so I may have spent a little more time on sanding these than I needed. For me that converts to about 1.53 six packs lol
     
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  20. Aug 8, 2016 at 10:32 AM
    #20
    ColoradoTJ

    ColoradoTJ I'm a boob guy.

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    1.53 six packs...LMAO. Great!!!

    Glad you picked up on my weird sense of humor.

    The eyelids look sharp and like when people DIY projects.

    I have to be honest though, before I opened this thread, I thought it was one of those eyelashes girls put on their cars. Thankfully, you maintained your Man Card and upgraded to Platinum.
     
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  21. Aug 8, 2016 at 10:37 AM
    #21
    boardude

    boardude [OP] I am Batman!

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    Ahahahaha My wife would divorce me if I were to even own a pair of those eyelashes. I think our sense of humor is pretty similiar, just like our names (my name really isn't Batman, its Kris).
     
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  22. Aug 8, 2016 at 10:41 AM
    #22
    ColoradoTJ

    ColoradoTJ I'm a boob guy.

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    So would mine. A few things were mandatory before my wife would walk down the isle with me:

    - If I spent more than 1K on a wedding ring for her, she would say no.
    - No minivans ever...no. matter. what
    - No station wagons...ever.
    - A DUI would equal an immediate divorce.

    I thought that was reasonable.
     
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  23. Aug 8, 2016 at 10:56 AM
    #23
    boardude

    boardude [OP] I am Batman!

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    Compared to some of the requirements I have heard from friend's wives, that is very reasonable lol! My wife would agree with all those especially your 2nd and 3rd points. When we had the "Do you want kids" talk when we were dating the next question was "would you ever own a mini van?". I grew up in late 80's Astro vans and when I told her that it almost ended our courtship lol.
     
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  24. Aug 8, 2016 at 11:03 AM
    #24
    ColoradoTJ

    ColoradoTJ I'm a boob guy.

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    Isn't that a fact. My wife's best friend requirements is a page long, (no kidding) and on that page is a 7 carrot diamond. She is always wondering where all the good "brothers" are at. I just laugh and say "guess they are all gone, can't imagine why you can't find a man with that criteria?" :rolleyes:
     
  25. Aug 8, 2016 at 11:08 AM
    #25
    boardude

    boardude [OP] I am Batman!

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    haha yeah that requirement alone might reduce your match.com results to single digits lol. We went cheap with the ring and spent the money on the honeymoon and mas tequila instead.
     
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  26. Aug 8, 2016 at 4:35 PM
    #26
    Krazie Sj

    Krazie Sj Resident Jackass

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    Extremely well done. My only gripe is you should have made a cast mold after they dried to sell to peps. Send them just the rough primed shells. When I got my Trex lids for my Taco, that's all they were. 7 years and still going strong on my Taco.
     
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  27. Aug 8, 2016 at 6:08 PM
    #27
    boardude

    boardude [OP] I am Batman!

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    Yeah I actually thought about that since there isn't anyone else making these but I travel for work pretty often, sometimes every week. Don't really want a second job right now lol
     
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  28. Aug 8, 2016 at 6:15 PM
    #28
    ColoradoTJ

    ColoradoTJ I'm a boob guy.

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    But then you can "make it rain" and say "I'm rich bitch!"
     
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  29. Aug 8, 2016 at 6:26 PM
    #29
    boardude

    boardude [OP] I am Batman!

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    Hahaha classic!!

    Sh*t I would probably just accept BevMo or Total Wine gift cards to keep my "project" beer fund going lol
     
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  30. Aug 8, 2016 at 6:56 PM
    #30
    ColoradoTJ

    ColoradoTJ I'm a boob guy.

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    I see no harm in doing that as well.

    You're throwing the bomb ass parties for all Tundras.com members once a year right? Have a huge meet and greet, BBQ, and some damn good laughs.
     
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