In the mill, I used a 1/4" mill bit and a couple different countersink bits to get the bevels. There ended up being a lot of metal chips on the floor.
The finished lamp next to the old bezel / lens that disintegrated when I took it off to paint the interior.
A pic showing the recesses milled into the back so the lamp holder would fit flush under the bezel.
The lens is a piece of 1/4" lexan that I milled a step in to fit through the bezel's face. To make it opaque I taped off the front face and bead blasted the back side.
Mocked up in the truck after getting a five minute pollish job on the buffer with white compound.
Hooked up to see how much light it was going to throw out. It works pretty darn good, a lot better than the stocker.
What's hard to believe is even for a part as simple as this there were around 40 different steps that had to be done correctly or it was junk. I screwed up bad one time and broke a bit when I was cleaning off the excess from the back and didn't pay attention to the feed rate and hammered the bit into the stock because the rate was around 28fpm instead of the 7fpm I was milling at... I did get the refresher I needed so all around it was a good day.
Jamie
:stupid: those would sell good. how much does the aluminum run?
S