Larry Mullen posted:Thanks so much, Pete. So you used the original Lionel headlight platform? I will have to research on here your method of the headlight lens.
I did keep the original platform primarily because of the number plate and emblem. To make a lens I just measure the diameter of the opening. Then find a drill bit with the same diameter. Chuck it up in drill press or drill motor backwards and file, sand, and polish the back end to an acceptable radius. Then find a piece of steel or brass at least 1/8" thick and drill a clean hole in it with that same drill. Reverse the drill and start punching out lenses.
Pete