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#1
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Ever tried to cut a taillight lens?
Can it be done (cleanly)?
I have two broken w123 wagon tail lamps that I would like to make into one for the moment.... I once experimented, years ago, on one off a volvo using a dremel with a cutting wheel but it just melted the plastic into a mess.
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![]() Mac 2002 e320 4matic estate│1985 300d│1980 300td Previous: 1979 & 1982 & 1983 300sd │ 1982 240d “Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22 |
#2
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This is extreme make over.
Never done it as I would try to pull one from a JY. I would expect it can be done with a good hack saw. Can you do a test cut, just cut away the broken part, but not the intended line and see how it looks? You probably need to sand the cut line then glue the 2 halves together. Interested to see the end result.
Good luck.
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Not MBZ nor A/C trained professional but a die-hard DIY and green engineer. Use the info at your own peril. Picked up 2 Infractions because of disagreements. NOW reversed. ![]() W124 Keyless remote, PM for details. http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/334620-fs-w124-chasis-keyless-remote-%2450-shipped.html 1 X 2006 CDI 1 x 87 300SDL 1 x 87 300D 1 x 87 300TDT wagon 1 x 83 300D 1 x 84 190D ( 5 sp ) - All R134 converted + keyless entry. |
#3
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The saw adapter has a spring loaded guard so it's pretty easy to expose just enough blade to get the cut done without having a crasy spimming blade waiting to amputate a finger! Last edited by FYVMMF; 04-15-2013 at 06:55 PM. |
#4
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Agreed, the melting is caused by the tool spinning too fast or if it were a band saw, same idea but in a straight line.
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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual. ![]() ..I also have a 427 Cobra replica with an aluminum chassis. |
#5
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i would be tempted to use a fine-toothed blade, maybe a masonry blade, on a chop or miter saw. leave enough room for the kerf to be melted and messed up and when you get the burned plastic piling up at the edge it can be wirebrushed off before gluing. paramount would be cutting a straight line, which is what i think would be hard to achieve using a dremel.
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#6
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You would have a better chance of cutting a straight line with a Hack Saw using a fine tooth blade. Also you wouldn`t get the plastic hot.
I think Acitone would work to attach the two pieces together. that would depend on the type of plastic I would guess. Charlie
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there were three HP ratings on the OM616... 1) Not much power 2) Even less power 3) Not nearly enough power!! 240D w/auto Anyone that thinks a 240D is slow drives too fast. 80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works |
#7
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I wonder if he is waiting on the free 300TD rear passenger tail light lense from me to attempt this procedure.
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daw_two Germantown, TN Links: Sold last car --- 05/2012 1984 300D Light Ivory, Red interior No longer selling Cluster Needles Paint No longer selling New Old Stock (NOS) parts Past: 3/2008 1986 300SDL "Coda" 04/2010 1965 190D(c) "Ben" & many more |
#8
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HEAD BANG So didja ship 'er yet ![]()
__________________
![]() Mac 2002 e320 4matic estate│1985 300d│1980 300td Previous: 1979 & 1982 & 1983 300sd │ 1982 240d “Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22 |
#9
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Melting plastic is due to high cutting speed. Cutting by hand with a fine tooth hacksaw would work, make the cut further towards the bad section allowing you to finish sand. ( A hack saw will give you a straight cut where the rotary tool won't )
The plastic is very brittle so don't put too much pressure on the cut. If you were using the brown / black abrasive cuttings wheels, they cut by abrasion rather than cutting chips increasing heating. |
#10
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those tiny saw blades work great for plastic. I use them routinely for interior trim modification, and even used them when repairing my Euro headlamps and for the HID retrofit in my Sebring. I use a generic set from Horror Fraught, and this leaves me with no safety guard, so I use only my cordless Dremel with them because it lacks the torque of the corded beast.
Also, anyone that thinks a straight line can't be cut with a Dremel just hasn't learned the trick, yet. I do it all the time, and consistently, at that. You have to keep your eye ahead of the cut, Kinda how you watch down the road as far as possible while driving. (Unless you just stare at the tail lights of the car in front of you, in which case you are probably doomed to never make a clean cut with a Dremel.)
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- K.C.Adams '77 300D Euro Delivery OM617 turbo / 4-speed swap 404 Milanbraun Metallic / 134 Dattel MB-Tex Current status: * Undergoing body work My '77 300D progress thread |
#11
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Water jet will cut just about anything, initial cost is probably a bit high. If you go to home cheapo, you should find a coping saw set, about $10, will get you a coping saw and several coarse to fine blades. Mark your cut, take your time. Seen lots of failed attempts to bond to taillight plastic. Might scuff a spot and use JB weld or some epoxy. 5 minute epoxy will yellow, I don't know if polyester resin will.
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CC: NSA All things are burning, know this and be released. 82 Benz 240 D, Kuan Yin 12 Ford Escape 4wd You're four times It's hard to more likely to concentrate on have an accident two things when you're on at the same time. a cell phone. www.kiva.org It's not like there's anything wrong with feeling good, is there? |
#12
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at this point, just buy a good used one. Your time should be factored into the cost and if my time spent hacking a part together is more than buying a good used part or new is more then I just buy the new part.
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#13
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Good grief... those lenses are turning into gold by this point. Upon my return to the US I may coordinate a group purchase at $50-$70 a piece brand new. If that does not drive the prices down, nothing will!
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[GONE] - 1995 Mercedes E300 Diesel - 130k miles - Smoke Silver (702) over Mushroom leather (265) - Bladder blasting, coast-to-coast work machine. |
#14
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Teye-eye-eye-ime IS ON MY SIDE! Yes it is
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I second the fine toothed hacksaw followed with the sandpaper. Much more control over everything. It only takes one misplaced oversized tooth to catch the plastic and ruin your donor piece. Tool and piece in a fixed position to help with straight edges. Think meat slicer here. Belt sander on low speed sounds perfect. Can they be run slow enough? MBZ123
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1987 300SDL "Rhona" 218k 1986 300SDL "Johanna" 166k - Abducted 5/15 outta SFV Reward 4 info 1984 300TD "Petra" 212k - Parts yard pirate, arrrrgh 1982 300CD "FrankenFemme" 178k - Eyes only TS-XWRKS transplant abomination (loc. classified) 1980 230CE "Lulu" aka "Terminal" 277k - Dying the slow death 1985 300CD "Gerda" 203k - She ain't playin' SOLD 1983 300TD "Svetlana" 240k...and pleading for more. SOLD "What a heavy load Einstein must've had...F&@%!NG morons everywhere!" - David Lynch |
#15
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Quote:
![]() I tried to buy one off a guy who was parting two w123 wagons on the parts for sale subforum. I got this like, dude, like rant, like dude, like it's cold dude and I been skiiing all day so like dude I want like $80 plus one hour labour plus postage to pull it 'cause it's cold outside dude. Any reasonable, not-substance-altered humans on this list want to sell a decent one... drop me a line ![]()
__________________
![]() Mac 2002 e320 4matic estate│1985 300d│1980 300td Previous: 1979 & 1982 & 1983 300sd │ 1982 240d “Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22 |
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