Make your Own Marchal Fog Light Covers for Fox Mustangs

my89notchback

my89notchback

Club Member
I have an 86 Mustang GT. The fog lights are really expensive to replace, and typically come without the covers. Which was the case with mine. I refused to pay $100 for plastic covers, so I made my own.

Trace the lights on a piece of cardboard. You want the cover to be slightly larger than the housing. Cut them out. Cut out a 1 1/2" x 12 " strip of cardboard to create the sides of the cover and tape the two pieces together with masking tape. Trial fit the cover to the light.
 
Next you are going to cover them with fiberglass. Cut out a piece to glass big enough to cover the front. Paint the cover with resin and place the glass mat on it and smooth it out and then give it another coat of resin.

Next cut out a 1 1/2" strip of fiberglass mat to cover the sides. Repeat the same process.
 
The next thing I did was to give each cover a second coat of resin. I painted both sides with resin this time to seal the cardboard from water. You don't want to get carried away because you are making a cover not a Bayliner! So the one piece of matting will be enough to give it rigidity and make it impact resistant.

After they dry, trim off the overlap from the front face to the sides and give them a quick block sand with 8o grit paper.
 
Now give them a coat of body glaze filler to smooth them out, block sand and repeat to fix any low spots.

Give them a few coats of sandable primer, reblock them and paint them. I clear coated mine to get them to look a certain way, but it isn't necessary.
 
I added a Ford logo to mine rather than take the time to hand paint the Marchal logo, but to each his own.

There you go. $35.00 and some time.
 
Thanks. I just thought this could be usefull to some of you guys with these cars. The price they get for these covers is ridiculous. Shoot me a PM if you need help.
 
You must log in or register to reply here.
Back
Top