Creating a lightweight headlight for your race car is very easy. Here's how to move out of phase one and into phase two of prepping the new replacement light, using my Type R Swapped Civic Coupe race car's headlight as the example.
STEP 7: Place the first coat of paint on the back side of the lens. This is so the paint doesn't chip from flying rocks or any other moving debris you may encounter while on the race track.
STEP 8: Add a second coat of paint, making sure to get into all the corners and crevices. This is to prevent any light from bleeding through.
(For reference, here's a comparison between the original broken light and the new replacement.)
STEP 9: Install the new light back into the car, then you are done!
The benefits of using an actual headlight (instead of repairing the old one or creating a new one by hand or with a 3D printer) is consistency. It wouldn't be that hard to make a mold of the lens itself, but the back side (where the mounting tabs are) is very complex. It would take multiple molds and then the parts would have to be bonded together.
Using an actual headlight ensures the piece fits--and I'm using minimal effort to do so. Also, time is important. Saving time on small tasks mean you can spend the extra time on other, more urgent needs.
Tips, tricks, wins, and learnings. Go behind-the-scenes at the race shop and the track with Boehm Motorsports.