Two Color Lens Fiat Adjusted Copy

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Fiat Topolino
Brake and Turn Signal two color lens.
Part 2: Casting the Lens
With the clay removed and the cleaned female side, the mold is now ready to cast the first part of the two color
casting. This lens uses 35G of both A and B of Alumilite Water Clear and to achieve the right color for the brake light
half of the lens. 4 lines 7/8 inches long on the specula is used to achieve the right color for each casting. The specula
with the red dye is then rubbed against the side of the stir cup after the two parts are poured together. Not all the dye
will come off the specula, but enough to create the correct color and each lens is the same.
#15
#16
Here the blocking part of the mold has been
removed and as you can see the blocking of the
resin into the top half of the mold has been
effective. The PVC piece was put between the
red and amber halves of the mold to keep resin
from filling up in-between the two mold parts
where the styrene piece was inserted when
making the mold. Although very thin it will still
take a large amount of resin to fill the space
between the two mold parts which is not wanted.
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#17
This shows the blocking mold just as it was
removed from the top half of the lens mold. The
PVC piece is still in place and the red resin has
made it’s way all around it.
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#18
Here the PVC piece (that was inserted before the
resin was poured into the mold ) is peeled away
from the red side of the mold with little effort (the
PVC piece was trimmed so it did not go all the
way up to the sides of the female part of the mold)
This was done to make sure there will be red cast
for the Amber to adhere to when the second half
of the mold is poured.
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#19
Now, clean up is necessary and by using a small
nipper to cut away flash and extra resin that builtup because the insert was not all the way out to
the edge. If your mold allows you to have the PVC
insert go all the way out to the sides and bottom of
the mold then there will be less clean-up. Make
sure there is available casting for the other side to
attach itself or there will be two parts instead of
one.
#20
This picture shows how easy the upper half of the mold was to clean up
after using the blocking mold.
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#21
The same amount of Water Clear is used for the upper part of the lens. But only one line 7/8 inch
long of Orange dye is used to achieve the correct amber color. Again the specula with the orange
dye is then rubbed against the side of the stir cup after the two parts are poured together. The
red half of the mold has some residual heat, so only the male side for the amber part of the
mold is heated in the Microwave for 50 seconds.
After curing in the compression pot
for 2.5 hours the top half of the two
color casting is complete. Note
there is flash to be cut away where
the styrene piece was used to make
the mold but it is thin and can be
removed with a nipper to make a
smooth cut.
#22
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Out of the mold, a toaster oven is warmed to 165
degrees and with the heating element off, the
lens sits on 4 thin metal strips so as not to stick
to the oven pan, for about a minute and then
checked. Sometimes two minutes are needed to
bring out the full gloss of the Water Clear. The
two color castings are now complete; if there are
some rough edges or drilling is needed even
buffing, wait for at least a day or two for the
casting to harden up.
Finished
by
Bill Colford
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