Headlight bezel screw hole shot!
Thread Starter
Racer
Joined: Oct 2008
Posts: 276
Likes: 5
From: Aptos, CA
Headlight bezel screw hole shot!
One of the molded screw holes in my driver-side headlight bezel has cracked and is now too large to accept the screw head which can't grip the plastic and hold it in place...
It should look like this...
Any ideas on how I can rebuild the material maybe with an epoxy?
It should look like this...
Any ideas on how I can rebuild the material maybe with an epoxy?
Melting Slicks
Joined: Jul 2009
Posts: 3,264
Likes: 3
From: Vero Beach FL
I would just use epoxy as you mentioned. Others have used it on the metal ones when the threads were stripped.
I was thinking about the head light brackets not the bezel itself, but it still might work.
I was thinking about the head light brackets not the bezel itself, but it still might work.
Last edited by Roco71; Jan 10, 2012 at 04:22 PM.
Thread Starter
Racer
Joined: Oct 2008
Posts: 276
Likes: 5
From: Aptos, CA
Yeah I think I might be able to even copy the shape with cutting up some pieces of card stock and using epoxy.
It's not under too much stress especially since the opposite hole is in tact. Just need a surface for the screw to grip.
It's not under too much stress especially since the opposite hole is in tact. Just need a surface for the screw to grip.
Thread Starter
Racer
Joined: Oct 2008
Posts: 276
Likes: 5
From: Aptos, CA
Clever! I think if trimmed down the anchor could replace and recreate the missing shape pretty well. I might give that a try!
What size did you use? I need to take the screws to the store to measure the threads anyway as I need to re-tap or helicoil one of the holes in the aluminum housing. They should have cast a metal bracket to add support. Oh well, that would have been extra $
What size did you use? I need to take the screws to the store to measure the threads anyway as I need to re-tap or helicoil one of the holes in the aluminum housing. They should have cast a metal bracket to add support. Oh well, that would have been extra $
Team Owner
Joined: Jan 2006
Posts: 37,637
Likes: 3,118
From: Crossville TN
Get a flat washer that will allow the screw shank to pass through it, but is large enough to cover the enlarged hole. After wire brushing the back side of the hole and the washer, attach it to the back side of the bezel with JB Weld putty epoxy (stick type). Leave enough excess epoxy on the washer so that it fills that hole; then use a toothpick to clean the area for the 'repaired' hole. Use some touch-up paint to recolor the epoxy that shows on the bezel face, when the epoxy hardens. Those screws are not meant to have much torque applied to them (10-15 in-lbs; about 1 ft-lb); so be gentle when you install the screws so that you don't pull your repair out.
Team Owner
Joined: Aug 1999
Posts: 30,995
Likes: 99
From: Ontario
Clever! I think if trimmed down the anchor could replace and recreate the missing shape pretty well. I might give that a try!
What size did you use? I need to take the screws to the store to measure the threads anyway as I need to re-tap or helicoil one of the holes in the aluminum housing. They should have cast a metal bracket to add support. Oh well, that would have been extra $
What size did you use? I need to take the screws to the store to measure the threads anyway as I need to re-tap or helicoil one of the holes in the aluminum housing. They should have cast a metal bracket to add support. Oh well, that would have been extra $
Last edited by Paul L; Jan 10, 2012 at 07:14 PM.
Thread Starter
Racer
Joined: Oct 2008
Posts: 276
Likes: 5
From: Aptos, CA
Get a flat washer that will allow the screw shank to pass through it, but is large enough to cover the enlarged hole. After wire brushing the back side of the hole and the washer, attach it to the back side of the bezel with JB Weld putty epoxy (stick type). Leave enough excess epoxy on the washer so that it fills that hole; then use a toothpick to clean the area for the 'repaired' hole. Use some touch-up paint to recolor the epoxy that shows on the bezel face, when the epoxy hardens. Those screws are not meant to have much torque applied to them (10-15 in-lbs; about 1 ft-lb); so be gentle when you install the screws so that you don't pull your repair out.
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Thread Starter
Racer
Joined: Oct 2008
Posts: 276
Likes: 5
From: Aptos, CA
Success! I used the JB Stik technique with great results. I first attached a 8-32 washer to what remained of the original drilled hole. When that cure I shaped some more to cover the opening. When it all cured I sanded it to shape with my Dremel.
Oh and I also drilled a hole in a block of scrap wood, filled it with JB Stik and tapped a 8-32 thread in it. I was curious to see if I could thread in a machine bolt and pull out the threads with my bare hands. I could not.
If you strip the bezel mounting holes in the aluminum casting, you could either tap to a larger size (IE 10-32) or re-tap 8-32 using JB Stik. I have no doubt the the threads could handle the load of the lightweight bezel.
I guess you really CAN tap threads in JB Weld. Just don't over torque...
-Brad
Note: The block of wood is making a cameo appearance in the background of this picture.
Oh and I also drilled a hole in a block of scrap wood, filled it with JB Stik and tapped a 8-32 thread in it. I was curious to see if I could thread in a machine bolt and pull out the threads with my bare hands. I could not.
If you strip the bezel mounting holes in the aluminum casting, you could either tap to a larger size (IE 10-32) or re-tap 8-32 using JB Stik. I have no doubt the the threads could handle the load of the lightweight bezel.
I guess you really CAN tap threads in JB Weld. Just don't over torque...
-Brad
Note: The block of wood is making a cameo appearance in the background of this picture.
Instructor
Joined: Jan 2012
Posts: 201
Likes: 0
From: some hole in the ground town- camp verde:) arizona
well i'll tell ya wut i do with problems like this. put a piece of hay bale string next to it n light a match. i melt in some more plastic to this spot n let it harden. it's great too cuz they make hay bale strings in every color u could want. i even used this to repair a broken fan shroud. it held fine til i kicked it to get it in place. big mistake there. have done this to repair the plastic grill inserts too, but it's hard to make that look good
