I thought I would post how I reworked the fender to accept to Sprite taillight.
First, I marked its location, drilled a hole for the jigsaw blade, and cut the edge I had marked.
Attachment:
Taillight Start of cut.jpg
Then, I used a couple of rubber pieces to hold the top of the flap out to about the angle I need to have the taillight sit correctly.
Attachment:
Taillight with spacer 1.jpg
Attachment:
Taillight with spacer 2.jpg
Next, I needed to remove the curve in the flap. So, I used a 1700watt HF heat gun to relax the fiberglass. It does not take very long. Be careful you do not cause the gell coat to bubble, it can occur quickly (ask me how I know?).
Attachment:
Taillight heating.jpg
I then check to see if I have it about where I want it and that the flap is reasonably flat.
Attachment:
Taillight trial fit.jpg
I then start to apply glass mat and resin to fill and shape the gap to a shape I like. I applied a couple of layers, sanded and then added some pieces of foam as a filler. Then I covered the foam with more mat & resin and sanded again.
I know have something I can work with. I will use filler to finish it in the final shape I want.
Attachment:
Taillight area shaped.jpg
I preferred the original style lights and I will upgrade the bulbs to LEDs. Since I have a 3rd brake light from the Jeep Wrangler spare mount I am using, I am not too worried as to how bright they are.
Attachment:
Spare tire mounted.jpg
Next, I will pull the left front clamshell fender and see if I can flatten the curve to make it match the other side, (older fender that had, somehow, lost some of its shape), fender I had bought and found it was flatter (wider at the widest width). Hope I can, the wider size covers the tire fully. I also will make some stiffeners for the underside of the fender where the front stay bolts thru to reduce the flex. I made a trial unit today using some 1/4" X 1" flat steel about 15" long. Working from the middle of the bar mounted in my vice, I gripped the other end with a large crescent wrench and started to bend it. I then moved it out, about 1" at a time, until I had the curve I needed. The I flipped it around and worked the other half. I then drilled a 1/2" hole for the thru bolt and mocked it up. Even without it being glassed to the fender, it really firmed up the whole unit!
More to come!