Repro SS/Rally parking lenses

[jade76]

Ok, I'm about ready to start making some up soon as I get the new material I'm going to use. Found this material which isn't bad, but remains someone tacky when cured and it's hard to get all the air out.

Anyways here's a sample of it, this one had a problem so it's not perfect as you can see, but otherwise is exact with exception of Part # which is usually worn off the originals anyways:

http://www.75-79novas.com/images/products/SS-Rally_lens.JPG

Once I get the lens right, I'll probably either offer to replace the lens on your old set or do it yourself. It's not real difficult to remove the lens, but the glue they used was definitely made to hold forever and if you're not careful you can crack or break the back in the process. Eventually I'll make some backs up too for complete lights.

They are also being put through some stress tests to find out heat and cold variances to make sure they don't melt or crack when subjected to weather and climate changes such as hot desert or cold winter climates.

[novabjovi]

Looks good to me. I sent you an email your pm box is full

[Canter]

good job! :)

[jade76]

novabjovi:

Looks good to me. I sent you an email your pm box is full

Had to clear it, should be able to send PM now. Didn't realize I had that many in there. lol

Thanks for the comments!

There's still room for improvement so the actual lens will be much better. I'm my worst critic so if I'm not happy with the results I won't offer them until they're perfect, at least as perfect as possible. I'm working on the taillight housings and lenses too, so I'll post them soon as I get my samples made up, probably within next 2-3 weeks.

[turbeauxfire]

Looking good, Tony! I'm real glad someone's doing this. I'll be real interested in both items!

[jade76]

Here's the Rally center flags I've been working on, while we're at it. The bowtie is a little off center on this one, but that has been fixed and are ready to go.

http://www.75-79novas.com/images/products/rally-flag.JPG

http://www.75-79novas.com/images/products/rally-flag2.JPG

2 different shots so you can see the reflective properties of it. They're not exact, but are still nice to give the emblems a restored look. These are actually done on 22 gauge polished silver aluminum and trimmed to exact size. Also have polished gold for custom look. You simply remove the old insert, restore the emblem, trim the insert if needed, set it in the center and pour Clear UV Epoxy (Available at local auto store for about $5) over it and let it cure. These will be offered as a set of 3 to do both fender and grille emblems.

[jade76]

The lens has been in the freezer now for almost 36 hours building up ice and frost and so far has no signs of cracks or stress fractures. That's a good sign. Gonna leave it in for 5 days, let it thaw and give it a heat test.

Not sure how hot to test it though. All plastic melts at fairly low temps, but I figure 140-150 F should do. If it's subject to heat any hotter than that it's probably on fire. lol

The resin I really want to use has a higher rating around 225-250 F, but also at 3 times the cost and my goal is to make something that is effective both in durability and cost.

[Novajay]

Tony,

Maybe get some heat lamps and fry it like the do at McDonalds! (hee hee)

Seriously, consider the harmful effects of UV light. Put it out in the sun with a reflective background for a week to see what happens. Or on a really hot driveway.

Just a suggestion.

[Green Dragon]

Here's the Rally center flags I've been working on, while we're at it. The bowtie is a little off center on this one, but that has been fixed and are ready to go.
2 different shots so you can see the reflective properties of it. They're not exact, but are still nice to give the emblems a restored look. These are actually done on 22 gauge polished silver aluminum and trimmed to exact size. Also have polished gold for custom look. You simply remove the old insert, restore the emblem, trim the insert if needed, set it in the center and pour Clear UV Epoxy (Available at local auto store for about $5) over it and let it cure. These will be offered as a set of 3 to do both fender and grille emblems.

Those are looking good.

Been kicking around the idea of casting those myself for a long time, same with the fender and trunk emblems.

which brings up my question - are you planning on (please, lol ) doing a matching insert for the trunk Rally emblem ?
( very rare early 77 only, far as we could ever find out ).

Sign me up for a set, especially if you have all 4 :)

~ AL

[jade76]

Jay: Yeah, the resin I'm going to use actually has a UV rating, but that's probably a good idea to put it out in the sun anyhow for testing. It averages around 90 in the shade and smog alert in Atlanta increases the heat index similar to wind affect in winter conditions, so it'll probably have same affect as a hot oven.

Al:

As a matter of fact I have a friend just bought a trunk emblem off ebay and wants me to make one for it, so once he brings it to me and I can get the exact measurements I will have them too. I may be seeing him tomorrow so it could be as soon as the end of the week.

I didn't even know they existed until a few weeks ago. I seen a couple but just thought someone mounted a fender emblem on the trunk lid, but they are actually a little smaller. I have a 78 Rally, so all I have is the fender and grille emblems with Chevrolet emblem on trunk.

[Green Dragon]

I didn't even know they existed until a few weeks ago. I seen a couple but just thought someone mounted a fender emblem on the trunk lid, but they are actually a little smaller. I have a 78 Rally, so all I have is the fender and grille emblems with Chevrolet emblem on trunk.[/QUOTE]

Yeah, myself, Scott at Novaresource and Ro at pontiacventuras.com (he's a rally nut,too), discussed it for months last year.
Both of the "pro's" had never seen one either, and thought is was a fender emblem added, etc.
After looking at dozens / hundreds of photos, etc it was generally agreed they look to be early 77 only ( possibly all 77, but we've seen 77 with the Chevrolet emblem ).
then just Chevrolet on 78's.

not sure why, I'm guessing myself that the tooling was damaged and instead of redoing the tool, they just dropped it.
also possible that, with 78's using the 3 light taillights, they just dropped it with the other design changes.

open to any input, etc - the more info we gather the more we can make logical conclusions on what / why things were done .

~ AL

ps: I remember that emblem on Ebay, bid myself, actually :-)
if it works out, let me know when you have that one ( and price / details ),if you wind up needing the trunk emblem I'd loan mine out, so keep me posted.

pps (lol) - are your inserts flat ? or are the 'crosshatches' raised ?
just wondering, if flat then thay could be covered with a clear acrylic or lucite same as the original, instead of the resin you note (resin will assuredly discolor / yellow with time, I'm afraid

[jade76]

pps (lol) - are your inserts flat ? or are the 'crosshatches' raised ?
just wondering, if flat then thay could be covered with a clear acrylic or lucite same as the original, instead of the resin you note (resin will assuredly discolor / yellow with time, I'm afraid

I'd love to make them original, but for the time they're flat. More for appearance than originality. You could use acrylic or lucite. I just suggested the UV Epoxy as a cheap alternative. Of course the key is UV, without that it won't last long no matter what you use.

[Green Dragon]

I'd love to make them original, but for the time they're flat. More for appearance than originality. You could use acrylic or lucite. I just suggested the UV Epoxy as a cheap alternative. Of course the key is UV, without that it won't last long no matter what you use.

nothing wrong with flat, in fact might make things easier - if they were bumped up / embossed then a flat sheet of lucite,etc would not fit over top.
if flat then a correctly cut ( milled) lucite or acrylic sheet might be a better bet than the resin you mentioned - just make it either a tight force fit intot he emblem or else glue it on lightly around the edges (same as OEM) .

keep us posted on testing , price /availablility,etc.

~ AL

[jade76]

Al,

Rally flags will be $10 for the fender and grille set which are available. $2 more for trunk emblem once I get the dimensions for it. The fender and grille set are a tight fit and can be trimmed with a good scissors or sheet metal snip if needed.

If you have the trunk emblem and a good vernier caliper and can get the exact dimensions of the inside area of the insert, I can just use those dimensions and make them up.

The reason I mention the resin is it's UV protectant and can easilly pour in on top of the insert and seal it in place once it's cured without having to cut or trim to size, at least until I am able to make them up to include with the flags.

[dunova1978]

Here's the Rally center flags I've been working on, while we're at it. The bowtie is a little off center on this one, but that has been fixed and are ready to go.

http://www.75-79novas.com/images/products/rally-flag.JPG

http://www.75-79novas.com/images/products/rally-flag2.JPG

2 different shots so you can see the reflective properties of it. They're not exact, but are still nice to give the emblems a restored look. These are actually done on 22 gauge polished silver aluminum and trimmed to exact size. Also have polished gold for custom look. You simply remove the old insert, restore the emblem, trim the insert if needed, set it in the center and pour Clear UV Epoxy (Available at local auto store for about $5) over it and let it cure. These will be offered as a set of 3 to do both fender and grille emblems.
How can I aquire a set of these

[Philip]

This thread is 2 years old and Tony hasn't responded to me in awhile. Check with Classic Industries they have been adding a lot of 4th gen parts to their catalog.