Factory Correct Replacement of Carello Side Marker Lenses

[chuck]

Here is an easy method of replacing round Carello side marker lenses with new factory correct lenses simply by inserting the replacements into the housing. No machining of the chrome retaining ring and no gluing required.

The two round amber Carello side marker lights on my 69 Spider Veloce had bleached a little over time and one of the red rear side marker lights had cracked. If anyone has tried to replace these side marker lenses with factory correct ones they know that replacement lenses of the correct shape and markings are hard to find. A friend forwarded me Osso di Seppia’s “Brian’s” weblink to his instructions for Carello side marker restoration. It was an excellent starting point. Nice job Brian.

Side marker light restoration

Here’s how I did it. I purchased replacement lenses from Yolanda at Aftermarket Reproductions as Brian suggested, a set of two amber and two red lenses. They are exact duplicates of the original Carello lenses in color, shape and markings. Very nice!

1) First, protect the chrome retaining ring from scratching and damage by working on a padded surface. Using a small hammer break the existing lens. Clear the border of the old lens from under the chrome retaining ring with a small screw driver and the hammer. Be careful not to dent or scratch the chrome ring.

2) Remove the elastomer gasket. Clean the gasket and inside the light housing. If the galvanized surface is corroded, now would be the time to paint it with reflective silver paint. A dark surface under the lens will darken the appearance of the lens once it is installed. In this case no painting was needed since the metal surface was still bright. This would also be a good time to polish the chrome ring or have it rechromed if needed.

3) Replace the gasket back into the housing.

4) Sand around the outer edge of the border of the replacement lens to reduce the overall diameter to about 1.56”-1.57”. Also make sure the bottom of the lens is free of excess material (flat). Do not sand the bottom edge of the lens excessively because it needs to fit snug to lock into the housing.

5) Place the lens in boiling water for 1-1/2 to 2 minutes. Keep it under water with tongs.

6) Wearing latex gloves and using tongs, Remove the lens from the water and dry it quickly. It will now be flexible, but will only stay that way for about a minute, so work fast.

7) Flex the lens and feed the border under the lip of the chrome retaining ring. Go around the edge, flexing the lens as needed until it is all in the retaining ring. It will snap back into shape. Make sure it is properly seated and make any adjustments.

8) Allow it to sit for a couple of minutes for the polyurethane to become rigid again.

This technique works because Aftermarket Reproductions uses polyurethane as their casting material. It may not work with lenses made from other materials.

My thanks to Yolanda for the idea on how to do this!

Aftermarket Reproductions
142 Nevada St.
El Segundo, CA 90245
Phone: (310) 322-8028
Fax: (310) 450-8125

They also sell other factory correct lenses for Alfa's

[wilkie]

Thanks, great tip! The complete lights, with lens and chrome bezel/retaining ring, are indeed impossible to find. I purchased some replacement lenses a while back from Aftermarket Reproductions, but was stumped over how to install them into the chrome housing. There was another tip posted by someone, but it involved cutting or grinding down a portion of the chrome, something I didn't want to get involved with.

Now I can finally replace my milky-amber side marker lights!

[ossodiseppia]

Nicely done, Chuck. As you said this is the perscribed method by Yolanda. I was skeptical of this method because I was affraid of really screwing up the shape of the lens.

I am glad Yolanda is still selling these. Rossano contacted her a while back and was told they were no longer being made. Sheesh!

I believe she also makes the tear-drop lenses for the Duetto.

Thanks for the share, Chuck.