In the evolution of many mild customs, a taillight change is necessary in order to improve the flow and lines of the car. Some ’50s cars, such as the ’51 Oldsmobile, came with some rather unattractive taillights, while others featured classic designs that were frequently swapped onto other custom cars. When Highway 99 Hot Rods started building Jared Roethlisberger’s ’51 Oldsmobile, a pair of ’54 Mercury taillights were found in a box of parts that came with the car and he decided to use them. Since every car and every taillight is different, making a swap like this always requires a bit of ingenuity and fabrication. Follow along as we show you how we cleaned up the rear quarters of Jared’s Olds by swapping the stock taillights for these ’54 Merc taillights.

We started the job with a...

We started the job with a pair of ’54 Mercury lenses and the ’51 Olds quarter-panels stripped of the factory taillights and trim. These lenses showed up with the car; thenightprowlers.com and mercuryland.com are two potential online sources.

The first step was to determine...

The first step was to determine exactly where we wanted to mount the lenses. Using a felt-tip pen, we drew a few options on the quarter-panel until we liked what we saw.

Continuing the mockup, we...

Continuing the mockup, we cut away some of the quarter-panel so that we could fit the lens in place to see how it looks.

The cardboard template was...

The cardboard template was transferred to aluminum, which was cut out and bent into shape.

By adding some duct tape to...

By adding some duct tape to simulate sheetmetal, we were able to determine how much of the lens we wanted to cover.

The reflector fit nicely into...

The reflector fit nicely into the lens. A hole for the bulb socket and mounting tabs will be added later.

Since we were starting with...

Since we were starting with only the ’54 lenses, rather than complete taillight assemblies, we needed to fabricate reflectors and mounting brackets for the lenses. We started by cutting out a cardboard template.

The reflector fit nicely into...

The reflector fit nicely into the lens. A hole for the bulb socket and mounting tabs will be added later.

We needed to build a framework...

We needed to build a framework surrounding the lens to mount it to the quarter-panel. This was made from 1/4-inch round rod and some small pieces of 18-gauge steel.

The pieces of the framework...

The pieces of the framework were tack-welded to the quarter-panel.

With the framework complete...

With the framework complete it was time to start shaping some sheetmetal pieces to blend the quarters and the lenses. Four pieces were needed for each quarter. We pounded the steel (18-gauge again) into shape over a homemade sand bag and then used a small power hammer to smooth out the pieces.

As each piece of the framework...

As each piece of the framework was added we kept checking the fit of the lens to make sure everything was OK.

As each of the pieces of sheetmetal...

As each of the pieces of sheetmetal started to take shape, they were trimmed to fit over the framework.

Notice where additional sheetmetal...

Notice where additional sheetmetal was removed below the lens, and upper and lower tabs were fabricated from 18-gauge steel to hold the lens securely in place.

We continued to form the four...

We continued to form the four sheetmetal pieces for each side, getting them closer to the desired shape.

Once the shaping and trimming...

Once the shaping and trimming was completed, we tack-welded the pieces in place and once again checked the fit of the lens.

Here you can see where we...

Here you can see where we had to make some relief cuts in the quarter-panel to make a smooth transition from the factory steel to the new pieces of sheetmetal.

The second side was a little...

The second side was a little easier than the first since we now had a model to use for reference. The only tough part was making them match perfectly.

One more test-fit of the lens....

One more test-fit of the lens. It’s starting to look like something now.

It looks a lot better after...

It looks a lot better after an expert application of a little body filler by “Rotten” Rodney Bauman.

Here it is with most of the...

Here it is with most of the welding completed. At this point we still had to add the previously made small framework pieces that fit around the ridges of the lenses. Each individual piece was welded in place separately.

Our custom taillight installation...

Our custom taillight installation is complete. How do you like the finished product?