Subject: Headlight Repair

[Pantelis Giamarellos]

I have used the same approach in order to repair a front light on my
sister's in law VW Polo (you do not have this car in the States I believe)

Found two pieces of 1.5mm thick metal, have bent it so that it formed a
tight U shape, drilled a larger hole on the upper part and a smaller one on
the lower part (close to the light cluster's outer covering) and fixed the
metallic bracket with a self tapping screw and epoxy putty (which have
worked well on this application)

Just be careful not to use a long self tapping screw that may damage the
inner reflector surface.

Take care
Pantelis

P.S. I have painted the metallic bracket in the light beige colour of the
light cluster's outter casing and it is almost impossible to distinguish it.
Working with a Dremmel tool for rounding the corners was a good thing also.
----- Original Message -----
From: Richard J. Andrews <tech at flashmail.com>
To: <C1J1Miller at aol.com>
Cc: <quattro at audifans.com>
Sent: Monday, September 16, 2002 9:16 AM
Subject: Re: Subject: Headlight Repair


> I purchase a set of 4kq h4/h1's for $100 with busted brackets.
> i repaired them all for around $20.
> i went to home depot with the light and found a suitable right angle piece
of
> metal (I don't recall what it was for, some bracket) after some work with
> the  bench grinder, drilling mounting holes and scuffing the plastic. i
> applied jb weld and then put the brackets in place, then put some over the
> brackets as well. 3 months later they are holding fine :)
> i honestly doubt these will ever separate from the housings unless the car
> has a front end incident. (knock on wood)
>
> but with a little ingenuity you can probably get something that will work
> out fine. The JB weld did the trick for me, but make sure and let them set
> up 24 hours before messing with mounting them.
>
> HTH!
> rich
> '86 4kq
>
> At 10:50 PM 9/15/02, you wrote:
> >In a message dated 9/15/02 10:36:57 PM Eastern Daylight Time,
> >200q20v-request at audifans.com writes:
> >
> >
> >Taka writes:
> >---
> >Has anyone successfully repaired the upper headlight
> >mounts for eurolights?
> >
> >I know this sounds like a question specific to my 200q,
> >but I know that the UrS headlamps use the same stupid
> >design- if you're not careful, it's easy to snap off the
> >cantilevered plastic top mounts of the headlamps.
> >
> >I need to find an epoxy adhesive or something similar
> >that can bond this plastic, as well as a suitable chunk
> >of plastic that I can bond to the top of the headlamp in
> >order to use the OEM headlamp mount screw to hold it in place.
> >
> >Any suggestions as to how to best accomplish this?
> >
> >I went to the FLAPS and the best I could find was 3M plastic
> >trim adhesive- the epoxies I've found all specifically said
> >they don't work with polyethylene or polypropylene plastics,
> >one of which I believe the headlamp housing to be, unless it's
> >some sort of glass-impregnated nylon composite.
> >
> >Taka
> >---
> >
> >http://www.loctite.com/pdf/bondingguide.pdf
> >and
> >http://www.loctite.com/literature/design_plastic.html
> >____________________________________________________
> >Chris Miller, Bolton MA USA, c1j1miller at aol.com
> >'91 200q20v ==> http://members.aol.com/c1j1miller/index.html
> >____________________________________________________
>
>
>