C3 Headlight Frame Repair
Thread Starter
Instructor
Joined: Sep 2006
Posts: 192
Likes: 0
From: Fort Lauderdale FL
C3 Headlight Frame Repair
Hello All,
Newbie here so please bear with me if this question has been asked before, I searched and have come up empty handed.
With regards to the headlight cover and bulb housing, mine are cracked horizontaly across the bulb housings thereby leaving the driving lamp on the armature and the highbeam on the top cover frame. The crack in the pot metal is clean, and lines up when fitted together.
Can this be JB Weld-ed or some other type of epoxy repair? Is this a common problem, if so what fix short of replacement have you found that works well?
Thanks
Newbie here so please bear with me if this question has been asked before, I searched and have come up empty handed.
With regards to the headlight cover and bulb housing, mine are cracked horizontaly across the bulb housings thereby leaving the driving lamp on the armature and the highbeam on the top cover frame. The crack in the pot metal is clean, and lines up when fitted together.
Can this be JB Weld-ed or some other type of epoxy repair? Is this a common problem, if so what fix short of replacement have you found that works well?
Thanks
Drifting
Joined: Jun 2004
Posts: 1,881
Likes: 9
From: staten island ny
Originally Posted by 75coupered
Hello All,
Newbie here so please bear with me if this question has been asked before, I searched and have come up empty handed.
With regards to the headlight cover and bulb housing, mine are cracked horizontaly across the bulb housings thereby leaving the driving lamp on the armature and the highbeam on the top cover frame. The crack in the pot metal is clean, and lines up when fitted together.
Can this be JB Weld-ed or some other type of epoxy repair? Is this a common problem, if so what fix short of replacement have you found that works well?
Thanks
Newbie here so please bear with me if this question has been asked before, I searched and have come up empty handed.
With regards to the headlight cover and bulb housing, mine are cracked horizontaly across the bulb housings thereby leaving the driving lamp on the armature and the highbeam on the top cover frame. The crack in the pot metal is clean, and lines up when fitted together.
Can this be JB Weld-ed or some other type of epoxy repair? Is this a common problem, if so what fix short of replacement have you found that works well?
Thanks
ESU
Melting Slicks
Joined: Apr 2004
Posts: 2,008
Likes: 38
From: Space Coast Gator Territory
My headlight housing was broken and repaired after an accident by the PO. The break was clean and a couple inches in front of the hinge area. A piece of sheet metal secured with pop rivets was used to mate the broken halves. The repair worked very well, but I have since had a buddy with a new TIG welder stitch the break. We decided to leave the pop riveted sheet metal as it was a neat and strong repair. As you suggest, JB Weld and some reinforcement metal would probably provide a strong repair as well. Just be sure to clean and scuff the area to be bonded. The farther beyond the break you are able to secure reinforcement metal the stronger the repair. JB Quick is not as strong as the original, if you decide to go that route.
Team Owner
Joined: Aug 2006
Posts: 24,125
Likes: 15
From: Columbia Missouri
Originally Posted by Red 69
My headlight housing was broken and repaired after an accident by the PO. The break was clean and a couple inches in front of the hinge area. A piece of sheet metal secured with pop rivets was used to mate the broken halves. The repair worked very well, but I have since had a buddy with a new TIG welder stitch the break. We decided to leave the pop riveted sheet metal as it was a neat and strong repair. As you suggest, JB Weld and some reinforcement metal would probably provide a strong repair as well. Just be sure to clean and scuff the area to be bonded. The farther beyond the break you are able to secure reinforcement metal the stronger the repair. JB Quick is not as strong as the original, if you decide to go that route.
Again, pics would help a lot. Thanks.
Thread Starter
Instructor
Joined: Sep 2006
Posts: 192
Likes: 0
From: Fort Lauderdale FL
a pic
Hi guys sorry for the delay, a family emergency came up.
I have a pic that better shows the cracked housing that I am referring to.
Red69 I believe had a similar break from his description. You can see in the pic that this break seperates the housing into two seperate pieces.
Curious if JB Weld and some back plate support would provide a trouble free fix.
How do I post a pic? I am not authorized to do so per my guide.
In the meantime here is a link to it: http://i89.photobucket.com/albums/k2...adlightass.jpg
Any opinions, input always appreciated
I have a pic that better shows the cracked housing that I am referring to.
Red69 I believe had a similar break from his description. You can see in the pic that this break seperates the housing into two seperate pieces.
Curious if JB Weld and some back plate support would provide a trouble free fix.
How do I post a pic? I am not authorized to do so per my guide.
In the meantime here is a link to it: http://i89.photobucket.com/albums/k2...adlightass.jpg
Any opinions, input always appreciated
Melting Slicks
Joined: Apr 2004
Posts: 2,008
Likes: 38
From: Space Coast Gator Territory
Sorry, but I cannot offer any photos of my headlight repair at this time. Your picture looks like there are only flat surfaces involved in the break. If that is the case, your repair would be simple. You seem to already have an idea on how to repair it and just need a little encouragement. I have used JB Weld to repair numerous items with great success. If you take the time to clean the area well and plan the repair well beyond the break, it should be strong as new. If you can get support metal on both sides of the break with JB Weld to hold them, you will be OK. If possible, keep each side one continuous piece. Use oakboard to make a template to guide you before cutting the metal. Before applying the JB, line everything and clamp in place before drilling a few holes for pop rivets to hold everything tightly. Be sure the light housing did not change dimension and still fits the opening. Once the JB Weld sets up it will be too late to change anything. While you have the light out is a good time to replace all the bushings and apply some lubricant.
Thread Starter
Instructor
Joined: Sep 2006
Posts: 192
Likes: 0
From: Fort Lauderdale FL
Thanks Red,
Just wanted to be sure that repairs like this are successfull and avoid the high cost of a replacement piece. I have had luck with JB before and will take some photos to document the repair.
Thanks
Just wanted to be sure that repairs like this are successfull and avoid the high cost of a replacement piece. I have had luck with JB before and will take some photos to document the repair.
Thanks
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Melting Slicks
Joined: Apr 2004
Posts: 2,008
Likes: 38
From: Space Coast Gator Territory
75, it appears if you cut the sheet metal carefully and fit the contours with a nice bend, your repair will not be noticable. Keep any rivets with the blind side out and it will be a clean fix. Touch it up with some duplicolor and it will be like new. BTW, NAPA can order you some duplicolor matching spray if you can provide the correct factory color code. Good luck with the fix!
