As much as it irritates the guys at the shop, we don’t throw anything away so you can imagine the boxes and boxes of “trash” that we have in the attic! Years ago we parted out an Alfa Romeo 1900 and I saved this blown out Carello Tail Light Control Relay Box. Its totally broken, missing the flasher part, the points are broken on the switches and the aluminum cover is gone but the brown plastic base is in decent condition. There was a big chunk broken out of it but the overall shape was good and the numbers were all crisp and clear.
Fast forward 15 years, we need to finish the restoration on the 1950 Ferrari 166 Berlinetta which requires this part to make the brake lights and turn signals work properly. I can’t find anyone with these parts so I am making one. With some polyester body filler (Bondo), I filled in the imperfections on the original part and made a “negative” to fit inside the hollow portion. Then I poured silicone mold making stuff around the part to pick up the numbers and details. Next, I poured in the brown-tinted liquid plastic that hardened to become the base of the relay box.
Making the aluminum cover was a pain in the neck because it has to be perfect with no file or sanding marks to look like it came out of a factory press machine. I sent some photos of the original part to the engraver who replicated the script perfectly.
Instead of using the electro-magnetic relays, I’m using a solid state controller hidden inside the box so that everything looks totally original from the outside while being a little less problematic on the inside.