I didn't make a lot of progress today (July 6, 2010) but I did make the hal-mark of any emergency vehicle: the light bar.
Here's my methood for scratch-building emergency vehicle light-bars, with some clear plastic knifes.
Before beginning, find photos and/or blue-print drawings of your chosen lightbar, to ensure accuracy.
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Step1: take 2 knives and glue them together blade-to-blade, using regular plastic cement (I use Testors. I tried this once before with white glue, and the glue didn't hold, and it remained tacky for weeks)
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Step 2: scribe the general out-line of the lightbar into the knife assembly, and cut it out, leaving some excess around the edge. You can use a Dremmel tool with a cut-off disc (and have it be reasonably safe, since you can hold it by the handle while cutting) but I couldn't find my safety glasses, so I used a hack-saw. Definately use the Dremmel tool if you can, as it will make this step go easier and faster
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Step 3: Once you finish cutting out the rough shape of the lightbar, sand it down to it's final size and shape, using corse sand paper (I used #80 grit, which seemed to work out great. You could go to #120 grit, but it would be a little slower, but easier to control. Anything less than #120 grit would be more effort than it's worth)
I sort of goofed while cutting out the light bar (as shown in the photo) and it left a huge notch in the bar. This can be fixed, if it's minor, should you do the same. Start sanding the goofed-side down with the sand paper before shaping the bar, and it should work.
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Step 4: Once you ginish shaping the light bar, dunk it in water to get rid of the sanding dust and residue, and dry it off with a paper towel. Once dry, paint it with transparent paint (Check your refrences for color) I don't have any on hand right now, but I'll get some Tamiya transparent red, since this will be mounted on a fire engine.
It's important to check sources on your light bars before building/painting, since there are neumerous types and styles (especially since LED bars came out) and the color is determined by state law. For example: here in Florida, amber is for tow-trucks and general construction, solid blue and blue/white is for police units, and solid red is for fire apparatus and ambulances.
This can be done in any scale, with any style of lightbar. There are some nice aftermarket ones out there, but they are not allowed in this GB, not to mention, they are not worth it unless you buy them in bulk, since Shipping often out-costs the acuall lightbar. Try it. It's fun.
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Step 5/ Up-date: I found another lightbar style that would work, if you can't find any transparent paint. Drill out locations along the bottom of the lightbar with a #61 drill bit in a pin vise, about 1/2 way through the bar. Then paint these holes with reguklar artist's acryllic paint you can find at Wal-Mart, according to refrences.