Headlight repair?

kis · Post by **kis** » Mon Sep 28, 2020 5:16 pm

Hi all, so I’ve got a headlight where the rear access cover clip has broken. I know you can get repair kits for brackets but what about the access panel part? Anyone know of a fix? As this part is under tension (in order to keep the rear cover securely sealed) just wondering how best to fix it? Also I’d like a ‘useable fix’ rather than silicone, etc. Cheers

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Z4C_er · Post by **Z4C_er** » Mon Sep 28, 2020 5:22 pm

If it's properly prepared, I think JB Weld is pretty unbeatable. I've been properly impressed recently. They even make a special plastic formulation as well.
You could even add a pin as below:

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Jfgoldfish · Post by **Jfgoldfish** » Mon Sep 28, 2020 5:35 pm

To give it the best chance of holding I would go for:
- small bit of quality epoxy such as JB weld in the opening.
- narrow hot staples straddling the split to provide the tensile strength.
- cover the staples in more epoxy and snip off or bend over the legs.

Z4C_er · Post by **Z4C_er** » Mon Sep 28, 2020 8:22 pm

Jfgoldfish wrote: ↑Mon Sep 28, 2020 5:35 pm To give it the best chance of holding I would go for:
- small bit of quality epoxy such as JB weld in the opening.
- narrow hot staples straddling the split to provide the tensile strength.
- cover the staples in more epoxy and snip off or bend over the legs.

Yep, the staples will be a good idea. if you don't want to heat them up you can drill 0.5mm holes and stick them in before covering in epoxy.

Jfgoldfish · Post by **Jfgoldfish** » Mon Sep 28, 2020 8:56 pm

Z4C_er wrote: ↑Mon Sep 28, 2020 8:22 pm Yep, the staples will be a good idea. if you don't want to heat them up you can drill 0.5mm holes and stick them in before covering in epoxy.

That would certainly work.

It would save the OP needing to buy a hot stapler or messing around with dodgy soldering iron methods!
I have made similar repairs by drilling a series of 0.5 holes and stitching the split together with 0.4mm stainless steel wire. Then a glob of epoxy for good measure.

Edit: I got my stainless from crazywirecompany on eBay. They sell all sorts of wires and meshes for all sorts of purposes.

kis · Post by **kis** » Tue Sep 29, 2020 10:57 am

Thanks for the replies/suggestions. Think I'll definitely give this a go as I've not really got anything to lose

My only concern is there isn't much material for me to drill really? Will see what I can do and will do a write up

Jfgoldfish · Post by **Jfgoldfish** » Tue Sep 29, 2020 11:54 am

kis wrote: ↑Tue Sep 29, 2020 10:57 am My only concern is there isn't much material for me to drill really?

You could drill down into the headlight housing on that side rather than trying to drill into the remaining stub. The epoxy will seal up the holes.

The key is to drill tiny holes. Less than 1mm ideally.

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