These are the parts Dodge should have made. They made stainless headlight rings as an option for the 2WD trucks and Power Wagons but the retainers were all mild steel. Quickly rusted and always look out of place painted. I decided to make some dedicated tooling to make/sell these as I thought others might want them. To make them exactly like originals takes quite a few steps and jigs so follow along as I take you through it. I'm currently selling them for $40.00 a set(enough for one truck)
Album by Kevin Foust. Photos by Kevin Foust. 1 - 9 of 9 Total. 1758 Visits.
1 This is the self contained punch and die set that makes the blanks. I punch them out on a 50 ton shop press. Rick T. Brad P. John H. helped me with some grinding. Ron F. and Martin W. helped with the die. The blanks are different sizes for each side due to one is tapped and the other is a slip through. I just grind them to whichever side I need.
2 The drill jig. I had Mark R. drill the holes on a CNC mill so they would be exact. 2 Holes were drilled in the top for alignment dowels. Two were tapped 1/4- 20. with one being overdrilled once in 2 pieces. I had it hardened then. I then sliced it in 2 pieces with a thin cut off wheel and ground surfaces completely flat again. I had to have dowels so I could perfectly align them when putting it back together. Wood spacer keeps them in place while doing the holes.
3 This is the bending jig that does both side of the curl bend. One is bigger than the other and goes in the opposite direction. Took a while to figure this one out and Walt P. Helped with some grinding on this. Part is bolted in the center slot and drums are turned with wrench. Hardened pin is Put in the the center to keep size true. Yes, it was involved to make this.
4 This is the die set that forms the curve so they seat on the stainless ring right. One punch will do both side as they are opposites as mentioned before. Dowel pins keep them in place and done on the shop press again.
5 Here is all the tooling at once used to make these. Notice how the metal feds though the die set.
6 here is what a finished set looks like.
7 My truck didn't use this style of rings as the militarys were smaller in diameter and bolted on. I found the if I pried up some of the tabs I could use the Power wagon rings if the were smaller. I cut a section out and riveted it on and it works fine.
8 Here's one of the tabs that needs to be bent out a little so the ring catches.
