I took the fiberglass tips off the shelf to fabricate the lenses for the nav/strobe lights. Vans must have been playing some kind of joke with me by sending one white and one grey wingtip. The good thing about the white one is it had already been sanded smooth at all the molding seams. I spent awhile wiht the orbital sander, followed by a hand sanding block; to smooth out the grey tip.
The lenses come out of a mold of a single piece. First step was to cut these in half. Next I layed a lens over the tip and traced a line along the bottom reveal. I cut the lenses using tin-snips. Next I traced a line along the opposite reveal and cut it out. Once these were close, i just kept going back and forth, about a half dozen times, fitting and trimming. Once they were acceptable, i put a very soft scotchbrite wheel in my drill press and used it to buff the edges.
Now just to figure how how to attach these and make them removable.
