RobinsVoyage
Fabricating PlexHeadlight Covers (Very cool) on Gen 1 Pajero
Last Winter, in the deserts of Arizona, my friend Brian decided to "help" me make headlight covers for my 1988 SWB... of course he has the tools and a steady hand, and is a perfectionist.. so he did the work himself... with me ah... supervising.. Here are some pictures of the step by step below. Enjoy..

First, take the headlight buckets out and trace a line on the plexiglass.
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Use a saw like this one to cut the shape.
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Sand the edges.
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Lay the bucket on your plexiglass and mark the holes for the screws
Do both sides at once, tape them together so they'll match..
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then put the other one down there and drill through the holes into the plexi into the opposite headlight bucket.
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Seal the drain holes at the bottom of the headlight bucket.. I don't have a picture of this.. I used black duct tape...
Remove the film off the plexiglass and screw them into the headlight buckets.. (That's me helping!)
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Wash them in the sink...
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Install onto the car..
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Put your grill back on.
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And you're done!... and people will ask where you got them. :)

-Robin