Headlight Lens Fix - Clip fixings - Wet headlight

Phil_B

Phil_B

Member
Hello, as with several other people, I had a very wet headlight on my Drivers side, so took it out follow the usual procedure documented on here. However, mine was not sealing as the fixing points for the metal retaining clips along the top had all broken, resulting in no pressure on to the foam seal strip and causing the actual unit to crack.
I do love to try and fix things, and make things as as may wel become apparent over the course of my A2 ownership.
If anyone else has had this, this is what I did:
Headlight Fix (1).jpg


Unit removed, and cover removed.

Headlight Fix (2).jpg

The broken fixing point.
Headlight Fix (3).jpg

Crack visible. Stress fracture.
Headlight Fix (4).jpg

Rubber trim gasket also in a terrible condition. I have plans for this...


Headlight Fix (8).jpg

More than one clip fixing missing!!


Headlight Fix (9).jpg

6mm thick polycarbonate (I Think, found a sheet at home), 5mm deep. I had "just" enough of the original fixing left know how deep to make it. I filed a slight under cut to give the clip something to grip on to.


Headlight Fix (10).jpg

I used super glue to attach, after keying the surfaces.



Headlight Fix (14).jpg

Black Sharpie, and all is good.
I haven't used any silicone grease/sealer yet. I want to see how much difference I have made.
So far, all is solid and not moving.
If I do this again to the other side, or these bits come off, I will buy and use proper polycarbonate cement. I've normally got some at home, but it had run out. These covers are Polycarbonate, denoted by >PC<

I did have a forum search, not seen any repairs like this before. Hope this helps people. I have quite enough of this sheet, so could post out bits if people need some :)
 
What are you planning to do with the rubber seal, just realised one of mine is shot.

Looks a good job on the plastic, I would get one of the those cheap plastic welder guns and embed a staple over the crack, they are a handy tool to have for fixing under trays and bumpers etc.
 
bye_bye_alfa said:
What are you planning to do with the rubber seal, just realised one of mine is shot.

Looks a good job on the plastic, I would get one of the those cheap plastic welder guns and embed a staple over the crack, they are a handy tool to have for fixing under trays and bumpers etc.
Click to expand...
For the rubber seal, I am thinking of using a mountain bike inner tube.
The very front edge needs to be neat and tidy along the bonnet edge. I'm going to measure the height of it, and see if I can get a tube the correct thickness. If not, will fold over and double up, creating a neat edge.
Downhill Mountainbike tubes tend to be much thicker than normal tubes. I have a few of those.
Although most bikes these days run tubeless, so you'd need to have a look around online to get one. Chain Reaction Cycles would be your best option.
There seems to be more room just behind the raised lip to add a reinforcing patch. I may cut out my shonky bit of rubber, insert a new piece and add a larger patch over the top.

Hot weld plastic staples.
They are really good, and surprisingly strong.
I have one, but didn't use that as the lens cover is very thin, even with my thinner staples I wasn't comfortable.
 
Update. We have had reasonable rain, and no condensation or moisture in the headlight. Near side still has a very slight amount, so will check that one out soon.
 
Would like to see pics when you've done your inner tube business. My gaskets are goosed.

I did have a look a day or so ago, and you can buy replacements for around £8/9 each.


I've been making use of the hot weld gun, as I had to be forceful getting the air filter lid off and broke a section, as the screw had corroded in the housing. Some PU glue and staples and it's good as new.👍
 
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