99-00 Civic Fog Lens w/ Polycarbonate - D-series.org

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Old 06-11-2019, 11:15 AM   #1 (permalink)
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Default 99-00 Civic Fog Lens w/ Polycarbonate

For a long time, I've had cracked/broken fog light lenses that were held together with clear tape. I decided to finally do something about it, and started searching for ideas. The plan I came up with was to get a sheet of clear acrylic (AKA plexiglass and cut some circles out of it.

1: Take out your fog lights are remove the broken lens. All I did was get a flat head screwdriver and pry. Doesn't have to be pretty, they're broken anyways. Some pieces broke off, which is fine, makes more room to pry inside the lens. I found a little slot in the bottom of the light housing to shove a screwdriver in, so that made things a little easier. Fwiw, I don't have OEM fog lights, they're aftermarket.
https://imgur.com/jMM2nAX
https://imgur.com/E8GZLTG
https://imgur.com/TF46Ehb
https://imgur.com/c0x1M88
https://imgur.com/ZZHEopy

2: Now you have the lens removed. Take this time to clean out the inside of the housings.
https://imgur.com/bZgQtc3

3: Now comes the acrylic. I got this for about $24 on Amazon.
https://imgur.com/fol7fya

4: Put a fog light face down on the sheet and trace a circle. It's fine if it's a little bigger, better bigger than too small.
https://imgur.com/xXh2B28

*CONTINUED*
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Last edited by ThumperCivic; 06-11-2019 at 07:26 PM. Reason: changed information
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Old 06-11-2019, 11:17 AM   #2 (permalink)
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5: Probably not the best tool for the job, but it's what I had. Take a saw (a Dremel with the right bit would probably work better) and cut the circle out. Then cut another one in the same way.
https://imgur.com/nrO8p8y
https://imgur.com/4KZy7mj
https://imgur.com/Yw8B6k6

6: File down the edges so they're smooth (not pictured) and test fit them behind the trim that goes on the bumper. You may need to file down more to make it fit a little better.
https://imgur.com/elDw7G1

7: Now, here I'm using silicone to stick the acrylic to the housing. This will make sure it's waterproof too. However, you'll notice I'm using black silicone. I'm only using it because it's what I had lying around. If you want a better look, get CLEAR silicone. Do as I say, not as I do lol.
https://imgur.com/aVRqfV4

8: Let it cure, and then reinstall!
https://imgur.com/XmyxWrb

Bonus: If you want colored fog lights, LaminX sells films that stick on and help protect the lens.
https://imgur.com/nBZszcd
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I'm Sean, meet Thumper:
2000 Civic EX coupe D16Y8 5MT
-Hawk HPS 5.0 pads/Duralast Gold Rotors
-Blox short shifter
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-Energy Suspension poly bushings
-eGay front strut bar
-4th gen Prelude front seats
-Koyorad radiator
-AEM Short Ram/Blox V-stack

Last edited by ThumperCivic; 06-11-2019 at 07:26 PM. Reason: Changed info
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Old 06-11-2019, 01:19 PM   #3 (permalink)
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You could get a piece of acrylic laser cut to size and shipped for less than 24$ FYI, and the finish on the cut edge will be mint.

You could also probably get a circle of glass water jet cut too if you wanted. That way it wont yellow with time or pit from stone chips/bugs.
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Old 06-11-2019, 01:30 PM   #4 (permalink)
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Quote:
Originally Posted by EFB055 View Post
You could get a piece of acrylic laser cut to size and shipped for less than 24$ FYI, and the finish on the cut edge will be mint.

You could also probably get a circle of glass water jet cut too if you wanted. That way it wont yellow with time or pit from stone chips/bugs.
I have glass fog lamps and they still get pitted from rock chips.
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Old 06-11-2019, 02:07 PM   #5 (permalink)
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Quote:
Originally Posted by EFB055 View Post
You could get a piece of acrylic laser cut to size and shipped for less than 24$ FYI, and the finish on the cut edge will be mint.

You could also probably get a circle of glass water jet cut too if you wanted. That way it wont yellow with time or pit from stone chips/bugs.
There ya go kids, do that. Didn't want to use glass because I didn't want broken glass if a big rock hits it. If you have a link to someone that laser cuts it, I'll gladly add it to my original post.
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2000 Civic EX coupe D16Y8 5MT
-Hawk HPS 5.0 pads/Duralast Gold Rotors
-Blox short shifter
-Exedy Stage 1 clutch
-Koni Yellows/Megan Coilover sleeves
-DC2 rear swaybar/BWR bracing
-Energy Suspension poly bushings
-eGay front strut bar
-4th gen Prelude front seats
-Koyorad radiator
-AEM Short Ram/Blox V-stack

Last edited by ThumperCivic; 06-11-2019 at 07:27 PM.
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Old 06-11-2019, 03:45 PM   #6 (permalink)
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Beware: some polycarbonanate products are not UV stabilised. These could go yellow quicker than the lights you have now.
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Old 06-12-2019, 01:21 PM   #7 (permalink)
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Quote:
Originally Posted by BeerDrinkin View Post
I have glass fog lamps and they still get pitted from rock chips.
Where glass can chip from contact, it's unaffected by smaller impacts while plastic will deform on some level from any impact. If you had a ball point pen and you push really hard on glass, nothing happens. Do it on poly carb and it'll dent it.

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There ya go kids, do that. Didn't want to use glass because I didn't want broken glass if a big rock hits it. If you have a link to someone that laser cuts it, I'll gladly add it to my original post.
Search "water jet cutting" or "laser cutting" in your area depending on whether you want glass or plastic. I live in a medium city in Australia and there's 5 options with 40kms.
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Old 06-12-2019, 07:26 PM   #8 (permalink)
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THICK clear vinyl film that is UV resistant works great for anti-rock chip.
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