LED Headlights: First they had pressed glass lamps (01), not efficient and a somewhat yellow light. Later appeared the halogen beam bulbs, H4, H7, with whiter light (02). The newest blue bulb should produce a cooler light.H4 is a dual beam with two connectors, H7 single a beam with one connector. Standard in FWL-cars there are two single H7 and two dual H4 bulbs.

Earlier I modified all pressed glass lamps to halogen H4, enabling to turn ON all 4 beams by a separate switch, for show or redundancy only (03).

Now the time has come to have really white headlights using LED technology. There are various devices on the market, some with built-in ventilator, and some without. As I don’t like something additional moving and noising, I preferred the LED beam bulb with a conventional heat sink module. As best for my purpose I found: Philips 9003 CSP H4 HB2 LED Car Headlight Hi/Lo Beam Bulbs 180W 18000LM 6500K (04). It has the same 3-pole connector as needed for my DODGE (and other FWL-Cars), enabling a direct connection (05).

As this modification needs some special approaches, some steps are presented more detailed.

First the entire headlight unit has to be pulled out, fixed by the 3 screws, and the back panel removed (06). As there is not enough space for the connectors behind the bulb, due to the cooling module, they have to be transferred outside the beamer housing. Fortunately the cable length of the LED unit just fits, as well the depth for the cooling module, straight correct (5mm!).

The original sealing rubber cannot be mounted as is, must cut and grind (07). A permanent (never-drying) flexible seal can be applied instead. Then the LED beamer has to be opened by unfasten the side screw (08), and unsolder the three wires (09). Inverse the rubber seal for mount (10), re-solder the wires, and fix the items as it was (11). Inverse again the rubber seal and spread the retainer springs for free positioning (12), and when LED Beamer is inserted fix it by clipping in (13), done (14).

The rear lamp panel can be linked in (15), the entire LED headlight unit is ready for install (16). Now re-mount this Unit by the 3 fixing screws, then connect the LED bulb, and the new beamer system is ready for operate.

As the bulb has two single LED arrays, the light emission with the reflector is according to the halogen bulb. This is a reference check (17). The earlier pressed glass lamps looked yellow in comparison to the halogen lamps. Now the halogen lamps seemed as well to shine quite yellow in comparison to the full white LED light (18). The improved lightning is impressive, for security, on road, at night – and for show (road pictures will be posted later on).

Another useful and outstanding feature, adaptable for most FWL-cars!  - SERGE -   ;)

(01 Pressed Glass Lamp.jpg)

(02 Halogen Headlight Bulbs.jpg)

(03 All Halogen Headlights ON.jpg)

(04 LED Headlight H4 Philips CSP.jpg)

(05 H4 Headlights connectors.jpg)

(06 Halogen Headlight Unit Rear View.jpg)

(07 Rubber Seal Diameter Cut and Grinded.jpg)

(08 Unfasten the Cooling Module.jpg)

(09 Ready for unsolder.jpg)

(10 Rubber inversed over Cooling Module.jpg)

(11 Rubber back for fixing.jpg)

(12 Retainer Spring Spread.jpg)

(13 LED Fixed with Retainer Spring.jpg)

(14 LED Headlight Side View.jpg)

(15 LED Headlight Unit Ready for install.jpg)

(16 LED Headlight Unit Front View.jpg)

(17 LED Alignment Test.jpg)

(18 Difference Halogen - LED Headlight.jpg)

01 Pressed Glass Lamp.jpg (62KB - 491 downloads)

02 Halogen Headlight Bulbs.jpg (77KB - 502 downloads)

03 All Halogen Headlights ON.jpg (111KB - 487 downloads)

04 LED Headlight H4 Philips CSP.jpg (106KB - 489 downloads)

05 H4 Headlights connectors.jpg (68KB - 494 downloads)

06 Halogen Headlight Unit Rear View.jpg (80KB - 495 downloads)

07 Rubber Seal Diameter Cut and Grinded.jpg (70KB - 487 downloads)

08 Unfasten the Cooling Module.jpg (62KB - 486 downloads)

09 Ready for unsolder.jpg (89KB - 475 downloads)

10 Rubber inversed over Cooling Module.jpg (66KB - 496 downloads)

11 Rubber back for fixing.jpg (55KB - 508 downloads)

12 Retainer Spring Spread.jpg (81KB - 494 downloads)

13 LED Fixed with Retainer Spring.jpg (54KB - 502 downloads)

14 LED Headlight Side View.jpg (77KB - 502 downloads)

15 LED Headlight Unit Ready for install.jpg (81KB - 496 downloads)

16 LED Headlight Unit Front View.jpg (87KB - 491 downloads)

17 LED Alignment Test.jpg (51KB - 482 downloads)

18 Difference Halogen - LED Headlight.jpg (72KB - 475 downloads)

Circular LEDs: Replacing the standard bulbs of the taillights by LED lamps, the overall light has become significant brighter, but the difference in intensity between position light and stop/directional light got somewhat reduced.

I found a circular red LED device (01), with a plastic carrier 60mm, fitted with a mini connector (02). Without the carrier it has an outer diameter of 59mm, fitting exactly in the inner groove of the taillight lens (03), being fixed with some glue. The cable is fed through the lamps housing (04), is connected separately, and can be disconnected at any time if needed, rear the lamp unit. When OFF, the LED is not noticeable from outside.

This a view at reduced camera (05). (road pictures will be posted later on).

Now the stop and directional light has become more accentuated - for the rear drivers highly spectacular (06)!   - SERGE -  

(01 Circular Red LED.jpg)

(02 LED with Carrier and Connector.jpg)

(03 Circular LED in Taillight Lens.jpg)

(04 DSC07835 Cable Feedthrough.jpg)

(05 Circular Red LED ON.jpg)

(06 Stop & Directional Light.jpg)

01 Circular Red LED.jpg (72KB - 499 downloads)

02 LED with Carrier and Connector.jpg (57KB - 478 downloads)

03 Circular LED in Taillight Lens.jpg (106KB - 510 downloads)

04 DSC07835 Cable Feedthrough.jpg (89KB - 499 downloads)

05 Circular Red LED ON.jpg (41KB - 499 downloads)

06 Stop & Directional Light.jpg (87KB - 524 downloads)

LED Headlights (Supplement): By turningthe seal rubber to the top position I found out, that the strongly fixed centering collar can be removed by twisting (01). It is designed that it cannot be remounted in the wrong position (02). Thus there is no need to disassemble the cooling module and unsolder the cable for put up the rubber.

Here a new reflector with convex glass as in older times, available as VALEO A082374 (03), including the seal rubber for H4/H7 bulbs (04). There is as well no need to cut out and grind the center as well, as for the one shown from the original sealed glass headlight. Together some less job for an upgrade to the assembled  (05).

The registration and licensing office commented: we highly appreciate the brighter LED headlight as equipped in new cars, for security reasons. They are approved with certificate by the car manufacturers.

For LED headlight kits actually there are still no certificates available, as usual for rim and tire kits. - SERGE - 

(01 Collar removed by twisting.jpg)

(02 Collar fixed in Reflector.jpg)

(03 Boxes VALEO 082374.jpg)

(04 Content with Seal Rubber.jpg)

(05 LED Unit with Convex Glass.jpg)

01 Collar removed by twisting.jpg (72KB - 692 downloads)

02 Collar fixed in Reflector.jpg (75KB - 705 downloads)

03 Boxes VALEO 082374.jpg (91KB - 703 downloads)

04 Content with Seal Rubber.jpg (78KB - 680 downloads)

05 LED Unit with Convex Glass.jpg (78KB - 659 downloads)

Various sizes and colors of LED rings are offered in eBay, mostly from China. Cannot post links, for they are timed-out shortly.  - SERGE -

Headlight Glass: According the suggestion of Sven (wizard) I mounted a convex glass beside a flat glass (01). As the flat glass has a border of 14mm and angled diameter, at a first glance, it seems to be bigger (02). But the embossement of the flat glass in comparison to the original sealed glass is about identical (03).

Convinced the suggestion of Sven, I switched all headlight reflectors from flat glass to convex glass (04) - and I like! Thanks to Sven.

Now the inner border of the chrome bezel has become visible again, as it was original (05), and the headlights here, as can be seen, are equipped with LEDs.  – SERGE -   

Technical information: The measured current consumption of the LED Headlight is 1.64A at 12.0 Volts, exact same value for both filaments, hi and lo, tested each single (06).

Further values: 10.0Volts/1.00A, 11.0Volts/1.99A, 13Volts/1.47A, 14Volts/1.38A. At 10 Volts the  intensity of the light start to reduce, under 9V unusable.

(01 Comparison Convex - Flat Glass ON.jpg)

(02 Comparison Convex - Flat Glass OFF.jpg)

(03 Embossement of the Glasses.jpg)

(04 Both Convex Glasses ON.jpg)

(05 Inner Border of Chrome Bezel.jpg)

(06 LED Current Consumption.jpg)

01 Comparison Convex - Flat Glass ON.jpg (84KB - 707 downloads)

02 Comparison Convex - Flat Glass OFF.jpg (92KB - 691 downloads)

03 Embossement of the Glasses.jpg (83KB - 726 downloads)

04 Both Convex Glasses ON.jpg (78KB - 679 downloads)

05 Inner Border of Chrome Bezel.jpg (86KB - 685 downloads)

06 LED Current Consumption.jpg (99KB - 702 downloads)

Hi Serge
Thanks a lot for sharing your improvements of the headlights. I think I could use H4 on my Beast, a H4/H7 system (like on your convertible) at my Letter and H7 head lights at my daily driver.

Of course I would like to install fan free illumination moduls like you did. For my daily driver I assume I need a conversion module as well to prevent CAN bus errors (due to the dramatically reduced current consumption and cold wire supervision when headlight is off).

Happy Restoring!

Dieter

LED Headlights (Instructions): Now I have got another set as spare parts from another supplier, this time with an instructions sheet (01). Could save some additional job getting this before!

Added as well a PDF-File, ready for printing (02).  - SERGE -  

(01 LED Instructions.jpg)

01 LED Instructions.jpg (149KB - 660 downloads)

02 LED Instructions 150dpi.pdf (200KB - 660 downloads)

Rubber of Windshield Washer Foot Control: Years ago restoring my car I replaced all rubbers by new repro ones, as the one of the windshield washer control (01). Most of them dissolved, became soft and sticky as a chewing gum, and thus deformed, as well this one, never applied this washer pump (02). As for the Headlight Beamer Switch I found various sizes of similar rubbers from 3M (03). I cut and grinded one of the size 30mm to fit around the foot lever (04).

Now mounted, this material will remain as it, not as original, but durable and fits optically to the neighbor switch.  - SERGE - 

(01 Repro Rubber Mounted.jpg)

(02 Repro Rubber Dissolved.jpg)

(03 3M Rubber Sizes.jpg)

(04 New Rubber Cut as Collar.jpg)

(05 New Rubber Mounted.jpg)

01 Repro Rubber Mounted.jpg (106KB - 660 downloads)

02 Repro Rubber Dissolved.jpg (70KB - 685 downloads)

03 3M Rubber Sizes.jpg (109KB - 649 downloads)

04 New Rubber Cut as Collar.jpg (57KB - 651 downloads)

05 New Rubber Mounted.jpg (95KB - 661 downloads)

Unique Lancer Emblem: Recently I found a Lancer Emblem as on my glove box (01), but in bigger size, approx. 5 inches tall, never seen before (02).

The first owner worked for Chrysler/Dodge in styling, back in the 1950's and 1960'. This emblem was a prototype designated for the rear fender of the 1959 Dodge to come, a previous version of the later D-500 Emblem. In fact, in comparison the knight has exact the same size as the D-500 Emblem, just other sided (03). On the back it had some clay, was hand-crafted and has 3 threaded holes for studs, not shelled as production emblems, correspondingly more heavy (04). Just the spear behind is missing, the clearance was already provided.

After restoring, adding mounting screws and painting, this Unique Lancer Emblem got a new look and ready for mount (05).

I found a nice place, in the center between the rear seats, by replacing the Round Knight Emblem, a spinner hubcap insert (06). To get this Knight Emblem somewhat steeped in the upholstery, I had added an electric cover behind, as shown (07).

Due to the sharp edges of the Unique Lancer Emblem I cut a protecting rubber with 4mm offset to prevent damages on the upholstery (08), then fixed it with stranded steel wires (09). Final Front View (10).

Now, this 1959 Dodge Custom Royal Lancer Convertible is fitted with a unique Original Lancer Emblem, another exclusive eye-catcher (11).  - SERGE -  :laugh:

(01 Emblem Glovebox.jpg)

(02 Big Lancer Emblem.jpg)

(03 Comparison Lancer to D-500 Emblem.jpg)

(04 Lancer Emblem Rear View.jpg)

(05 Restored Unique Lancer Emblem.jpg)

(06 Round Knight Emblem.jpg)

(07 Mounting Assembly.jpg)

(08 Rear Protecting Rubber.jpg)

(09 Fixing with stranded Steel Wires.jpg)

(10 Mounted Lancer Emblem.jpg)

(11 Final Panoramic View.jpg)

01 Emblem Glovebox.jpg (95KB - 678 downloads)

02 Big Lancer Emblem.jpg (105KB - 662 downloads)

03 Comparison Lancer to D-500 Emblem.jpg (100KB - 670 downloads)

04 Lancer Emblem Rear View.jpg (70KB - 649 downloads)

05 Restored Unique Lancer Emblem.jpg (63KB - 662 downloads)

06 Round Knight Emblem.jpg (82KB - 663 downloads)

07 Mounting Assembly.jpg (60KB - 663 downloads)

08 Rear Protecting Rubber.jpg (64KB - 679 downloads)

09 Fixing with stranded Steel Wires.jpg (62KB - 639 downloads)

10 Mounted Lancer Emblem.jpg (102KB - 654 downloads)

11 Final Panoramic View.jpg (118KB - 649 downloads)

Rear Center Armrest: Looking at the rear seats, now with the Unique Lancer Emblem, I feel something is missing: a Rear Center Armrest.

In the floor I found a Rear Center Armrest from a 560SEC Black, as once I had the idea to build all the sophisticated interior into the Dodge. Then I abandoned this project and sold all, except this part (01). I designed a bracket to fix it free of the two seat bodies, and removable at any time without tools (02), then bent it accordingly (03). Later the Armrest will be covered black and white with the original material as the front Center Armrest (04).

The bracket is partly black coated to be invisible, can see how the back seat fits in (05).

Now the rear seats looks more comfortable, not so impressive as the 300F ones, but as well full equipped and complete (06). - SERGE - 

(01 Rear Center Armrest MB560 Black.jpg)

(02 CAD Design Alu Profile.jpg)

(03 Bracket Check before Black coated.jpg)

(04 Front Center Armrest.jpg)

(05 Back Seat Mounted.jpg)

(06 Assembled Rear Seats.jpg)

01 Rear Center Armrest MB560 Black.jpg (68KB - 653 downloads)

02 CAD Design Alu Profile.jpg (65KB - 675 downloads)

03 Bracket Check before Black coated.jpg (93KB - 635 downloads)

04 Front Center Armrest.jpg (88KB - 648 downloads)

05 Back Seat Mounted.jpg (88KB - 651 downloads)

06 Assembled Rear Seats.jpg (97KB - 638 downloads)

Rear Center Armrest 2: I felt the complain of many of you about missing Originality.

Now I corrected it according the Front Center Armrest, first virtually by CAD and PS, later will become real (01).  - SERGE - 

(07 Assembled Rear Seats OR.jpg)

07 Assembled Rear Seats OR.jpg (101KB - 641 downloads)

Armrest Stainless Trim: The door panel armrests of the 1956 Dodge Custom Royal are fitted with a surrounding stainless trim (01) (02), pictures courtesy of Dave (56D500boy).

As I like this “Make-up” I was looking for original, used stainless trims (03). I found as well new, but shorter ones, not surrounding the armrest (04). For my 1959 DODGE Custom Royal I preferred these trims, feeling they look more decent.

The two pieces design of the armrest enable dual colors (05). Shape the new trim to fit the curve and simply fix it (06). This stainless trim can easy be removed. In direct comparison the effect is apparent (07).

A visible de-luxe aspect (08) (09), and an additional touch of extravagance for an extraordinary car (10).  – SERGE –  :) 

(01 1956 Dodge Custom Royal Armrest.jpg)

(02 Added Stainless Trim.jpg)

(03 Used Stainless Trim.jpg)

(04 New Stainless Trim Short.jpg)

(05 Armrest Disassembled.jpg)

(06 New Stainless Trim Fixed.jpg)

(07 Comparison.jpg)

(08 Assembly Mounted.jpg)

(09 Assembly Front View.jpg)

(10 Door Panel Final View.jpg)

01 1956 Dodge Custom Royal Armrest.jpg (101KB - 599 downloads)

02 Added Stainless Trim.jpg (87KB - 621 downloads)

03 Used Stainless Trim.jpg (53KB - 591 downloads)

04 New Stainless Trim Short.jpg (74KB - 605 downloads)

05 Armrest Disassembled.jpg (91KB - 604 downloads)

06 New Stainless Trim Fixed.jpg (80KB - 576 downloads)

07 Comparison.jpg (69KB - 578 downloads)

08 Assembly Mounted.jpg (110KB - 574 downloads)

09 Assembly Front View.jpg (108KB - 584 downloads)

10 Door Panel Final View.jpg (162KB - 574 downloads)

Your latest version looks white(r).

Depend on light: artificial light in room, neon day-light in garage, flash light,  setting brightness, foto filter . . .  and always same camera!

Then: armrest cleaned . . . a whiter shade of pale? 

(DSC01945Lcorr.jpg)

DSC01945Lcorr.jpg (63KB - 577 downloads)

Single Oval Exhaust Tips: As always shown in an earlier article in this thread, I presented my Dual Oval Exhaust Tips: 

http://www.forwardlook.net/forums/forums/thread-view.asp?tid=23691&start=138

Here is shown how the same stainless Exhaust Tip can easy be mounted in the single version, animated with CAD (2012/13).

It needs two holes and two screws, preferably M6 (01). The exhaust tip is fixed on the lower part of the tube at direct accessibility (02),

is best when positioned till the end of the tip (03). Then paint black inside the outlet. If the space requires it can as well be mounted on the other side,

or adjusted with distances. No cutting is needed.

Now the heat cannot affect the visible upper part of the Exhaust Tip, protected by the gap. it will always remain nice and shiny (04).

Many FWL.owner may like this simple solution.  – SERGE –  :)

N.B. Additional an eDrawing-file is added (2013)

Today I found another supplier, but exact the same device and at lowered price:

Endrohre Edelstahl AMG Style 350x85x58 oval

http://www.ebay.de/itm/JOM-Mercedes-Look-Sport-Auspuff-Endrohr-schrag-oval-85x58-mm-Edelstahl-gerade/

(01 Oval Exhaust Tip Dimensions.jpg)

(02 Oval Exhaust Tip RearView.jpg)

(03 Oval Exhaust Tip FrontView.jpg)

(04 Oval Exhaust Tip Outlet.jpg)

01 Oval Exhaust Tip Dimensions.jpg (68KB - 570 downloads)

02 Oval Exhaust Tip RearView.jpg (86KB - 555 downloads)

03 Oval Exhaust Tip FrontView.jpg (80KB - 571 downloads)

04 Oval Exhaust Tip Outlet.jpg (61KB - 553 downloads)

2018 SW13 2012-10-11 Oval Exhaust Tip.eprt (182KB - 570 downloads)

Jumbo Oval Exhaust Tip: As time goes, one’s view may change, progressing to other, new trends.

First I started with two slanted stainless tubes pushed over the exhaust pipe. Then came the dual round tips, and latest the dual oval exhaust tips, both presented in this thread.

The oval AMG style looks very sporty, but in dual somewhat too modern for an oldtimer.

Now I found what would better fit on my 1959 DODGE (except the original Exhaust Deflectors):

Because it is big I call it Jumbo Oval Exhaust Tip, in stainless steel, measured size 150x80x265mm, double layer, feather edge 16mm (01).

It looks compact, solid, traditional and is optically best suitable to big cars (02).

The fixing is provided by welding, offering diameters 60 – 50mm selected by cutting. The small diameter is exact the same as the exhaust tube (51mm) to be mounted. (03).

As I want all options for an easy positioning, turning, adjusting or removing I had to modify. The inlet diameter was manually cut around the upper part of the connection, then spreading (04). Upper, for the exhaust will move rather downwards the bumper. Adding a stainless bracket, the unit becomes ready for push over the uncut tube (05) and to be fixed (06).

Here adjusted in final position (07).

While the Dual Oval Exhaust Tips demonstrated speed and power, the new type represents rather a discrete grandness as in older times (08).  - SERGE -   :)

(01 Jumbo Exhaust Tip Front View.jpg)

(02 Jumbo Exhaust Tip Top View.jpg)

(03 Tubes same Diameter 51mm.jpg)

(04 Connection Cut and Spread.jpg)

(05 Ready for Mount.jpg)

(06 Exhaust Tip Fixed.jpg)

(07 Exhaust Tip Mounted.jpg)

(08 Jumbo Exhaust Tips Overall Rear View ZH.jpg)

01 Jumbo Exhaust Tip Front View.jpg (70KB - 573 downloads)

02 Jumbo Exhaust Tip Top View.jpg (84KB - 573 downloads)

03 Tubes same Diameter 51mm.jpg (68KB - 562 downloads)

04 Connection Cut and Spread.jpg (82KB - 562 downloads)

05 Ready for Mount.jpg (85KB - 559 downloads)

06 Exhaust Tip Fixed.jpg (82KB - 555 downloads)

07 Exhaust Tip Mounted.jpg (79KB - 568 downloads)

08 Jumbo Exhaust Tips Overall Rear View ZH.jpg (119KB - 546 downloads)

On special request: here the link of the supplier for the JUMBO Oval Exhaust Tips:

https://www.quality-tuning.eu/us/universal-stainless-steel-exhaust-tip-oval-155x75-l265-in60-50-double-layer

Note: no need to cut the exhaust tube.  - SERGE -  :)

Front Center Armrest: I remember when I got my Dodge many years ago: around the pivot axes the upholstery was broken due to friction with the angled bracket. This should never happen with the newly upholstered armrest. Here I present how I did.

I used two screws (M8) as axis fitted with a nylon bearing, and two nylon shims each side as distance (01) to preserve a minimum gap between bracket and armrest (02), avoiding any mechanical friction (03). To spread the strong bracket up to 2mm needs a heavy wrench tool (04).

Since then till today, the armrest moves smoothly up and down as on ball bearing, without risk of any damage (05).  – SERGE - 

(01 Fixing Items.jpg)

(02 Assembling.jpg)

(03 Gap to Armrest.jpg)

(04 Mounted Pivot.jpg)

(05 Front Center Armrest Positioned.jpg)

01 Fixing Items.jpg (96KB - 650 downloads)

02 Assembling.jpg (77KB - 575 downloads)

03 Gap to Armrest.jpg (72KB - 558 downloads)

04 Mounted Pivot.jpg (87KB - 555 downloads)

05 Front Center Armrest Positioned.jpg (85KB - 573 downloads)

Horn Ring Pad 2: The padless horn ring is found mostly in non Custom Royal Dodges. As they look heavy “chromy” I was thinking, how it could be optically upgraded.  

I designed in 3D-CAD two identical custom made pads without the center part (02), assembled them pinky colored to the horn ring picture (03). A flattened dual template was generated (04), as well a separate printable 1 : 1 PDF-File is added (14). 

Print-out and stick on an aluminium panel of 0.5mm, cut around with a metal-scissor (05), then manually pre-bend on an edge, aligned to the white center line. The reference length is 117.5mm. Fine grind and bend the two metal channels manually to fit on the horn ring (06), to be ready for coating (07).  Any material can be used for coating. I used the same vinyl as for the door panels, matching to the interior (08). The vinyl contour can be cut “in the air” with a standard scissor (09). Instead of using the Alu-Pads, carpet tape is applied to the vinyl pad for  direct fixing (10). Starting to join to the horn ring on the outer side (11). 

Now the naked horn ring has got a bikini. With some additional paint in the center (red and golden), the make-up of the horn ring may be accentuated (12). A reversible upgrade for non CR-Owners, as it would be original,. For comparison here presented just on one side (13). – SERGE - 

(01 Horn Ring Padless.jpg)

(02 Dual Horn Pad 3D-CAD.jpg)

(03 Horn Pads CAD in Pinky Virtual Mounted.jpg)

(04 Dual Template for cut Horn Pad.jpg)

(05 Cutting Alu-Pad.jpg)

(06 First Check.jpg)

(07 Cut and Bent Alu-Pads Ready for Coating.jpg)

(08 Black Vinyl for Coating.jpg)

(09 Cut the Vinyl Contour in the Air.jpg)

(10 Applying Carpet Tape.jpg)

(11 Join to the Horn Ring.jpg)

(12 One Side Lateral View.jpg)

(13 One Side Top View.jpg)

01 Horn Ring Padless.jpg (86KB - 580 downloads)

02 Dual Horn Pad 3D-CAD.jpg (110KB - 547 downloads)

03 Horn Pads CAD in Pinky Virtual Mounted.jpg (91KB - 559 downloads)

04 Dual Template for cut Horn Pad.jpg (59KB - 650 downloads)

05 Cutting Alu-Pad.jpg (93KB - 552 downloads)

06 First Check.jpg (111KB - 546 downloads)

07 Cut and Bent Alu-Pads Ready for Coating.jpg (52KB - 551 downloads)

08 Black Vinyl for Coating.jpg (92KB - 543 downloads)

09 Cut the Vinyl Contour in the Air.jpg (73KB - 535 downloads)

10 Applying Carpet Tape.jpg (83KB - 569 downloads)

11 Join to the Horn Ring.jpg (87KB - 573 downloads)

12 One Side Lateral View.jpg (81KB - 551 downloads)

13 One Side Top View.jpg (83KB - 557 downloads)

14 Dual Template Horn Pad L117.5 A4 300dpi.pdf (178KB - 557 downloads)

On Street: In WideView, from Original 1000mm/600dpi reduced to 500mm/72dpi, for it fits here. - SERGE -   

(01 1959 DODGE Custom Royal Convertible 500-72dpi.jpg)

(02 1959 DODGE Custom Royal Convertible styled 500-72dpi.jpg)

01 1959 DODGE Custom Royal Convertible 500-72dpi.jpg (174KB - 549 downloads)

02 1959 DODGE Custom Royal Convertible styled 500-72dpi.jpg (196KB - 547 downloads)

Push Button Labels 1: In an earlier thread Ishowed how to restore damaged buttons by grinding the front part down to a flat surface, as needed 1 – 2 mm, all the buttons same amount and put on stickers. 

 http://www.forwardlook.net/forums/forums/thread-view.asp?tid=23691&start=206 

Unfortunately the applied letters look different as original, for the same font could not be found. In the first part I present here in 3D-RealView how this fault can easy be corrected. Most is self-explaining by pictures. The second part will show the practical implementation including a printable template.

Original push buttons assembly (01), original buttons (02), grinded front (R40) to become flat (03), modeled letters R N D 1 2 with the appropriate color (04), applied on transparency (05), labels print and cut out (06). Exploded assembly with the labels (07), put the labels on the buttons  without any glue (08) or in front of the metal cap, and the new push buttons assembly looks as original, ready to mount (09).

 No tools, no dirty hands -  just a fine coffee along the way.  – SERGE -  :)

(01 Original Push Buttons Assembly.jpg)

(02 Original Push Buttons.jpg)

(03 Grinded Push Buttons.jpg)

(04 All Letters Modeled.jpg)

(05 Letters Applied on Transpareny.jpg)

(06 All Labels Cut Out Solo.jpg)

(07 Push Buttons with Label Exploded View.jpg)

(08 Labeled Push Buttons.jpg)

(09 Labeled Push Buttons Assembly .jpg)

01 Original Push Buttons Assembly.jpg (116KB - 543 downloads)

02 Original Push Buttons.jpg (108KB - 559 downloads)

03 Grinded Push Buttons.jpg (79KB - 557 downloads)

04 All Letters Modeled.jpg (38KB - 548 downloads)

05 Letters Applied on Transpareny.jpg (60KB - 551 downloads)

06 All Labels Cut Out Solo.jpg (43KB - 558 downloads)

07 Push Buttons with Label Exploded View.jpg (93KB - 555 downloads)

08 Labeled Push Buttons.jpg (84KB - 542 downloads)

09 Labeled Push Buttons Assembly .jpg (115KB - 546 downloads)

Armrest Stainless Trim 2: When I had coated the upper part of my black armrests to interior white vinyl, I found later a pair of earlier armrests in black, same shape but all in one piece, as spare parts to turn back to original if one day demanded (01). I grinded in water (P600) to remove signs of (lady) nails, and threated them to get the surface as new (02).

Meanwhile the purchased Mopar Stainless Trims (early Imperial) arrived and got polished (03). To mount straight and gapless was tricky, as the length was very tight: First bent both ends to fit in the armrest, grind the armrest 6 x 0.3 mm to fix the center position (04). When clipped in on both sides imposed to the body to get well centered (05). In comparison I found these Mopar trims better performing to my car (06) and replaced the recent shorter ones (07).

Now the armrests appear Mopar like, not just a nice add-on as before, but with an original option (08). - SERGE -    :)

N.B. On the earlier one-piece armrest these trims may have been used to hide the separation border on the partially coated, dual color versions.

(01 Pair of one-piece Black Armrest.jpg)

(02 Difference grinded in Water.jpg)

(03 Polished Trims.jpg)

(04 Ends Pre-Bent to fit.jpg)

(05 Trim Centered.jpg)

(06 Comparison Black-White Armrest.jpg)

(07 Comparison on White Armrests.jpg)

(08 Trim Assembled Final View.jpg)

01 Pair of one-piece Black Armrest.jpg (81KB - 542 downloads)

02 Difference grinded in Water.jpg (70KB - 552 downloads)

03 Polished Trims.jpg (76KB - 549 downloads)

04 Ends Pre-Bent to fit.jpg (99KB - 537 downloads)

05 Trim Centered.jpg (72KB - 572 downloads)

06 Comparison Black-White Armrest.jpg (93KB - 540 downloads)

07 Comparison on White Armrests.jpg (68KB - 571 downloads)

08 Trim Assembled Final View.jpg (161KB - 537 downloads)

STRETCHED 1959 DODGE Custom Royal Convertible: Not for thinking, just for look at!  - SERGE -  . . . . . . . . . . . . . . . . . . . . . . . . . .

Total length: Original 553cm, Strechted 658cm

(01 STRETCHED 1959 DODGE Custom Royal Convertible 600-72dpi.jpg)

(02 STRETCHED 1959 DODGE Custom Royal Convertible styled 600-72dpi.jpg)

(03 STRETCHED 1959 DODGE Custom Royal Convertible RH Handle 600-72dpi.jpg)

01 STRETCHED 1959 DODGE Custom Royal Convertible 600-72dpi.jpg (203KB - 552 downloads)

02 STRETCHED 1959 DODGE Custom Royal Convertible styled 600-72dpi.jpg (230KB - 535 downloads)

03 STRETCHED 1959 DODGE Custom Royal Convertible RH Handle 600-72dpi.jpg (204KB - 556 downloads)

SHORTENED 1959 DODGE Custom Royal Convertible: Why not the other way down: a Roadster?  - SERGE -  :cool:

Total length: Original 553cm, Shortened 488cm

(SHORTENED 1959 DODGE Custom Royal Convertible 450-72dpi.jpg)

(SHORTENED FLAT 1959 DODGE Custom Royal Convertible 450-72dpi.jpg)

SHORTENED 1959 DODGE Custom Royal Convertible 450-72dpi.jpg (202KB - 537 downloads)

SHORTENED FLAT 1959 DODGE Custom Royal Convertible 450-72dpi.jpg (189KB - 559 downloads)

"What type of solder and flux did you use?"

Sorrys Steve, I used the wrong expression: Not solder, but electro-weld. My friend did this on various point spots around, caring to keep the ring always centered. Fine tune by bending the fixing edges.

Good luck  - SERGE - 

1959 DODGE Paint Chip Set Ditzler: (as this seems to be forgotten, here again) This sheet shows the original color references on the various paint probes, individually stuck on a page.

Today the exact definition of colors is described by the additive RGB (Red-Green-Blue) or the complementary subtractive CMYK (Cyan-Magenta-Yellow-Key Black) codes, mostly used in the graphics industry and generated most programs with color options by entering the corresponding codes.

Using homogenous white light, a scanner delivers very accurate and reproductive results on a file. These can be used to verify or compare the color of a new paint with the original color. Just scan the new probe and compare the resulting color codes.

The Original Paint Chip Set for 1959 DODGE has been scanned at high definition and cleaned without affecting the colors. For homogenous results, the color codes then have been picked (50x50px) and the values insert in the attached Paint Chip, here at limited size (144dpi, 250k) in JPG (01) and PDF (02).

- SERGE -

(1959 DODGE Color Ditzler 144dpi.jpg)

1959 DODGE Color Ditzler 144dpi.jpg (214KB - 479 downloads)

1959 DODGE Color Ditzler 130dpi.pdf (237KB - 511 downloads)

You are right, Nick! Not correct proportion. Now I corrected it with the flat version based on your sample, the car length still remaining the same (488cm).  Thanks for your creative input.  - SERGE - 

BTW: Now this file with the many layers has a size of 3.9Giga!

(SHORTENFlat 1959 DODGE Custom Royal Convertible 450-72 moved rear axle.jpg)

SHORTENFlat 1959 DODGE Custom Royal Convertible 450-72 moved rear axle.jpg (193KB - 426 downloads)

1959 DODGE CUSTOM ROYAL ORIGINAL GOLDEN KNIGHT EMBLEM – KING SIZE: Now it is realized, here presented for the first time, and available in limited quantities, electric plated in glossy gold and some in glossy chrome.

3D-designed to fit on the 1959 DODGE front grille, thus very simple and fast to mount - without any tools. It can be added and removed at anytime, anywhere and without leaving any marks.

This typical emblem, an absolute eye-catcher, a visible upgrade, a jewel on your 1959 DODGE! (01) (02) (03). A product featuring SWISS Engineering and International Technology.

Some details of the high technical standard are shown in (04) (05) (06). The emblem will be shipped in a safe and secure box (07) (08). Send me a PM for actual availability and price.

The Mounting Instructions A5 are added. All parts of the set are listed (09), and the proceeding is illustrated (10). What a nice job! It looks as it was always there.

 When done: Your Golden Knight Emblem  -  now is ready to enjoy!

   -SERGE -

(01 Gold on Original Front.jpg)

(02 Chrome on Original Front.jpg)

(03 Gold on SM Front.jpg)

(04 Check Glossy Surface.jpg)

(05 Silver Rear View Solo.jpg)

(06 Dual Rear 3D-Print - Chrome.jpg)

(07 Shipment Box.JPG)

(08 Fold and push in.JPG)

(09 Instructions 1959 DODGE CUSTOM ROYAL GOLDEN KNIGHT EMBLEM 01.jpg)

(10 Instructions 1959 DODGE CUSTOM ROYAL GOLDEN KNIGHT EMBLEM 02.jpg)

01 Gold on Original Front.jpg (197KB - 350 downloads)

02 Chrome on Original Front.jpg (160KB - 380 downloads)

03 Gold on SM Front.jpg (171KB - 359 downloads)

04 Check Glossy Surface.jpg (104KB - 356 downloads)

05 Silver Rear View Solo.jpg (106KB - 364 downloads)

06 Dual Rear 3D-Print - Chrome.jpg (90KB - 363 downloads)

07 Shipment Box.JPG (186KB - 356 downloads)

08 Fold and push in.JPG (146KB - 363 downloads)

09 Instructions 1959 DODGE CUSTOM ROYAL GOLDEN KNIGHT EMBLEM 01.jpg (215KB - 362 downloads)

10 Instructions 1959 DODGE CUSTOM ROYAL GOLDEN KNIGHT EMBLEM 02.jpg (221KB - 359 downloads)

Golden Coating: On a 1959 Dodge Custom Royal, Scripts and some knights are original already golden: the Lancer Fender Emblem NOS (1), the knight on the steering wheel NOS (2), the script Custom Royal (03).

It is obvious that many owners as me, liked to have as well gold on all other knights.

I purchased worldwide up to 20 various sprays, all promising real gold effect – all a disappointment! I had to do it by myself, many years ago. In addition to the new Golden Knight Emblem on front grille (glossy electro plated),

previously presented, all other knights on the car should uniformly as well be golden. Here some golden coated samples on my car (4) to (13). Even the screws of the carburetors are golden (14). The aspect may vary according light and camera.

What you see is mostly over 10 years old!

Many times I have been asked for. Now, on special order, a set can be shipped combined in the same box as the Golden Knight Emblem (15). The quantity is limited. All details are summarized in the attached application (16). - SERGE -

Another exclusivity for your outstanding 1959 Dodge!

(01 Lancer Fender Emblem NOS.jpg)

(02 Steering Wheel NOS.jpg)

(03 Script Custom Royal.jpg)

(04 Knight on Front Medaillon.jpg)

(05 Emblem on Door Panel.jpg)

(06 Emblem on Glovebox.jpg)

(07 Rear Trunk Emblem.jpg)

(08 D500 Emblem.jpg)

(09 Knight on Wheel Cover.jpg)

(10 Unique Emblem.jpg)

(11 Emblem on Ash Tray.jpg)

(12 Round Center Emblem.jpg)

(13 Dodge FWL Emblem.jpg)

(14 Screws on Carburetors.jpg)

(15 Combined Shipment.jpg)

(16 Application Golden Coating.jpg)

01 Lancer Fender Emblem NOS.jpg (113KB - 360 downloads)

02 Steering Wheel NOS.jpg (167KB - 353 downloads)

03 Script Custom Royal.jpg (123KB - 378 downloads)

04 Knight on Front Medaillon.jpg (128KB - 362 downloads)

05 Emblem on Door Panel.jpg (120KB - 364 downloads)

06 Emblem on Glovebox.jpg (161KB - 364 downloads)

07 Rear Trunk Emblem.jpg (95KB - 364 downloads)

08 D500 Emblem.jpg (130KB - 353 downloads)

09 Knight on Wheel Cover.jpg (111KB - 369 downloads)

10 Unique Emblem.jpg (126KB - 358 downloads)

11 Emblem on Ash Tray.jpg (153KB - 358 downloads)

12 Round Center Emblem.jpg (128KB - 355 downloads)

13 Dodge FWL Emblem.jpg (134KB - 370 downloads)

14 Screws on Carburetors.jpg (214KB - 352 downloads)

15 Combined Shipment.jpg (140KB - 360 downloads)

16 Application Golden Coating.jpg (157KB - 360 downloads)

Bullets for Rear View Mirror2: Bullets in metal have been presented earlier in this thread. 

http://forwardlook.net/forums/forums/thread-view.asp?tid=23691&start=128

They are not only very nice when mounted (01), but the metal point is rated as dangerous in a case of collision. The logic conclusion is to replace them by rubber bullets:

- Take small rubber bumpers, L15mm x D15mm x M4, they fit exatly to the mirrors diameter (02)

- Grind them down to your preferred shape using a portable drilling machine (03)

- Remove the metal bullets and mount the rubber bullets - done! (04)  

As the two bullet types are interchangeable (05), one set is kept in the glove box for replace at any time.  Of course, the mirror can as well instantly be restored to original (06).

Another "HighTech" solution?    - SERGE -   ;)

(01 Metal Bullet Mounted.JPG)

(02 Small Rubber Bumpers.JPG)

(03 Grinding the Rubber Bumper.JPG)

(04 Rubber Bullet Mounted.JPG)

(05 Comparison Metal - Rubber.JPG)

(06 Original Rear View Mirror.JPG)

01 Metal Bullet Mounted.JPG (147KB - 405 downloads)

02 Small Rubber Bumpers.JPG (87KB - 395 downloads)

03 Grinding the Rubber Bumper.JPG (200KB - 389 downloads)

04 Rubber Bullet Mounted.JPG (154KB - 393 downloads)

05 Comparison Metal - Rubber.JPG (87KB - 405 downloads)

06 Original Rear View Mirror.JPG (154KB - 409 downloads)

Danis Golden Knights: Today Dani (Daniel 1959) visited me with his recently acquired 1959 Dodge Custom Royal to pickup the ordered Golden Knight and a Set of Golden Coating.

At place we mounted the Golden Knight, and to demonstrate how easy is to apply the Golden Coating the knight on the medaillon was instantly goldened (01).

What a new feeling for the owner, now to drive with this visible upgraded car (02). At home he will as well golden coat all the other knights (emblems, wheel cover, . . .).

Another applied "Make-up" of an outstanding  1959 Dodge Custom Royal.  - SERGE -  

(01 Danis Golden Knights.JPG)

(02 Danis Golden Knights.JPG)

01 Danis Golden Knights.JPG (216KB - 409 downloads)

02 Danis Golden Knights.JPG (194KB - 399 downloads)

I got multiple  requests for stand-alone orders, for other cars or other purposes. I was thinking about have come to the decision to sell it ONLY together with a Big Knight:

- Send alone is too risky because of the international restrictions (chemical items)

- The reasonable amount doesn't comply to the extra effort for packing in a separate box, labeling, registering and bringing to post

- I have about twenty of them, anyway not enough to satify the demand. Just enough for forward looking 1959 DODGE owners

- Shipping together with the Golden Knight (on demand) is the same, the special box is safe, item can be declared as "repair kit"

This special colloidal solutiion I mixed about 20 years ago for my own purpose, by adding various pigments, again and again . . . still to get the most authentic gold tone. Finally it accumulated up to 500cl.

It doesn't peal, it doesn' crack, still looks golden after many years.  - SERGE -   :)

Speedometer 4: The characteristic of the coil-spring determines the sensitivity of the instrument. The more weak the spring, the higher is the displayed value. The more strong, the lower will be the displayed value.

The adjustment is shown on a speedometer of a 1959 Dodge. After remove the unit, the coil-spring is easily accessible from the side (01).

Can state as well: The longer the active coil-spring, the softer it will be, the shorter then the stronger.

By removing the splint-pin, the end of the coil-spring can be moved in for shortening, or out for extending the active lenght. To start, a difference of 2mm is recommended to estimate the final position.

Mostly the speedometer shows rather a higher value, the length of the active coil-spring then should be shortened by pushing in the end (02 zoomed left). Don’t cut!

Before testing, the zero position must be adjusted, as now this may have changed somewhat. Turn the entire spring unit using a needle as illustrated (02 zoomed right, and 03). The spring-coil should be kept absolute centered as shown!

Now the speedometer is ready for a check. Zero correct setting for Dodge 1959 is shown in (04). It will need 2 – 3 attempts to find out the exact displayed value.

Notice: the diameter of the tires influences the speedometer and the odometer simultaneously. The odometer should prior shoukld be right and can only be adapted by changing the gear. 

Another useful instruction.  – SERGE –   

(01 Spring Assembly.jpg)

(02 Adjustments.jpg)

(03 Set Zero Position.jpg)

(04 1959 Dodge - Zero Correct Setting.jpg)

01 Spring Assembly.jpg (151KB - 350 downloads)

02 Adjustments.jpg (164KB - 372 downloads)

03 Set Zero Position.jpg (148KB - 364 downloads)

04 1959 Dodge - Zero Correct Setting.jpg (98KB - 355 downloads)