My front headlights have dropped about a cm in the corners, and after further investigation I have noticed that the top supporting bar that is glued to the fiberglass has corroded and is begining to come away.

Reading around, this seems to be a common enough issue. What are the options here? Can you get a replacement bar and glue it in, or do I need to cut a custom piece of metal to replace it with?

Any advice / or alternatives would be greatly appreciated.

I'll post pics later so you can see the problem.

 

Yes , I believe that the support beam is available. If you can't find one, I have good used ones at my shop and will be willing to sell you one if needed. It is a REALLY fun job and will take some time to make sure that you get it into position and bonded correctly. I would be willing to help you in this matter also...if needed. I have done way more than one in my career and can help you in this matter if you choose to do it yourself instead of trusting it to a body shop. The choice is yours,,,,needless to write.
"DUB"

 

thanks for the reply, yes thinking I'm going to try and do this myself ideally.

What needs to come out in order to get access - do I need to pull the radiator, etc?

dont suppose there is a guide on the procedure anywhere?

 

IAn,
No the radiator does not need to be removed.
I will PM you on what to do in order in to get the beam out and a new one prepped and bonded in place. It is going to be a pain, because the headlight assemblies need to be removed so you can get the beam out without any problems. I will get to you soon. with the procedure..

Let me know if you are going to get a beam through Ecklers, etc.
"DUB"

 

Out of curiosity Dub, how much does a job like that cost as opposed to just a basic epoxy job?

 

Dub,

that's great, appreciate that thanks.... Another opportunity to get my hands dirty!

I didnt know if you could buy a replacement support bar - can you supply? I'm in Ireland btw, so will need shipping costs etc

Rowan.

 

Jeff79",
It all depends on the manufacturer you are using and the cost of the application gun required,(if any). It has been so long since I purchased my guns that I truely can not ermember what they cost. It is a part of my profession so I really do not dwell on their cost because the constant use of them makes it worth while in purchasing.

The epoxy can run you around $100.00+/- for two tubes, You may only need one, but having a back up is always wise.

Now the cost of having it done it truely another issue. Just packiing epoxy in the area of delamination will or may hold for a while, but to truely bond it, the area that the adhesive bonds to has to be CLEAN and properly prepped. This usually requires the support beam to be removed. Each car is different and ther has been a very few cases where the bonding area of the support beam where it is closest to the headlight doors was no longer bonded, but the area at the hood gap was still intact. Prepping the beam and body panel while the support beam was tilted downwards did allow me to clean it properly and yet still allow me to inject the adhesive. Usually when one side of the beam delaminates, the other is usually not to far away from it also, but remember I do not own a functional "crystal ball", this is my past experiences talking to you.

The amount of time required deals with a few issues that are important and need to be perfromed so the beam can be removed and if you are planning this task, PM me and I can fill you in. Depending if EVERYTHING went well and ther was no problems, I could easily have a full day in this repair , so with materials and labor $500.00+/-. But remember if it is a rust bucket and has been exposed to salt, some of the required fasteners will take more time to remove and if not break off and need to service/ replace other parts.
"DUB"
"DUB"

 

Replacement bar is available from Zip for $80

 

I picked mine up at Corvette Central,
make sure to paint it with Epoxy paint or Por 15 before you install it for corrosion protection. I replaced mine while the body was off and the rad support removed so access was pretty straight forward.
You may want to clean up your lights while they're out and repace some bushings and seals(available at vendors) Enjoy!