EDIGREG wrote:Cutoff is obviously way better without the lenses, but light distribution is much better with. Pretty bad hotspots without.
How are you making your own lenses? Pouring glass?
I noticed that as well Ed. What do you think, just run the glass?
I planned to make a mold of the headlight and vacuum-form acrylic over the mold: http://www.hidplanet.com/forums/showthr ... ing+lenses" onclick="window.open(this.href);return false;[/quote]
Yeah - I'd just run the glass. It's not ideal but the hotspots are going to be just as bad with a flat lens... the lens needs texture to diffuse the light. I would at least try it with the glass and see how it looks.
If you could mold some strategically-placed ridges into the plastic lenses that would be best. Clear glass at and above the cutoff, and vertical ridges below to diffuse the light:










