[s-cars] Headlight Repair - how to fix it with no tab

[chris chambers]

S- nutz,

I have been contemplating how to fix my headlight assembly, the tab was
broken off, but I didn't have the tab. see pics of broken tab:
http://photobucket.com/albums/v48/chrisanjenn/?action=view&current=brokentabrearMedium.jpg

http://photobucket.com/albums/v48/chrisanjenn/?action=view&current=RepairedtabMedium.jpg


Luckily my wife has a UrS4, see pic of tab we want to duplicate:
http://photobucket.com/albums/v48/chrisanjenn/?action=view&current=brokentabrearMedium.jpg

Now this is what I did, first I removed both headlight assemblies.
I coated the part of her tab I wanted to duplicate with petroleum
jelly.
 
Using modeling clay ($2.00) I carefully "wrapped" the factory tab to
form a mold. Now because the clay is soft I inserted cu-tips (with the
tip cut off) into the clay to use as handles. 

Now using my trusty dremel I opened up my broken tab into the empty
cavity next to it. see pic here 
http://photobucket.com/albums/v48/chrisanjenn/?action=view&current=TabguideMedium.jpg

I then moved the clay mold to the broken tab being careful not to
distort it. I carefully opened up the clay area of the mold that would
become my tab. I wanted to have a bigger tab that I could then file
down to size.

I used a 2 part plastic epoxy (plastic fusion) purchased at home depot
for $3.99 and filled my mold and both the cavity before the tab and
above the empty cavity. See noted above pic

After the epoxy has cured, I pealed off the clay to reveal my new tab!
http://photobucket.com/albums/v48/chrisanjenn/?action=view&current=RepairedtabMedium.jpg

I did have to file a small bit to fit just right, but that took maybe 2
minutes. Unfortunately I didn't think to take pics when I had teh clay
mold in place, but it is easy and self explanatory. I did make my mold
in 2 pieces, then joined them together on my broken headlight.


I know this write up is fairly basic, but hopefully it helps someone.
If you have any questions by all means ask.


Chris
Just trying to give back to the list

--- Igor Kessel <KBATPO at comcast.net> wrote:

> Folks,
> I have received a few requests for the repair procedure. I have
> finally gotten 
> around to writing it up.
> =============
> 
> Broken tab repair.
> 
> I had accidentally broken off the top outer tab on my RH side Euro
> headlight. Here 
> is what I've done to repair it.
> 
> 1. Degrease everything, including the area surrounding the broken
> tab, the tab 
> itself ad the broken off piece. Some rubbing alcohol will do fine.
> 
> 2. A long time ago I purchased a roll of the gooey rubbery compound
> that secures 
> the 200 taillight to the rear of the car. I used a small bit rolled
> into a ball in 
> my fingers to secure the broken off piece to the remainder of the tab
> so that they 
> lined up perfectly.
> 
> 3. I used some wide folded into a "V" painter's paper masking tape to
> create a 
> casting on both sides of the tab. The tab itself was molded with a
> cavity on the 
> top, thus creating a natural concave bed for the epoxy. With two
> pieces of masking 
> tape on both sides I have effectively created a "bathtub" if you
> will.
> 
> 4. Set the headlight on the bench absolutely flat and as close to the
> horizontal 
> level as possible. Shim it up if you have to.
> 
> 5. Mix a small amount of fast drying Armstrong epoxy and pour it into
> the 
> "bathtub" filling it up. It will spread evenly under the force of
> gravity. You 
> want it to fill up the concave cavity in the tab, but not to overflow
> and cover 
> the speed nut for the mounting screw on its end.
> 
> 6. After the epoxy hardens enough to hold its own you may carefully
> remove the 
> piece of the black gooey stuff from under the tab.
> 
> 7. Double, no, triple check that the makeshift masking tape casing is
> intact and, 
> most importantly, that it seals the volume between the tab and the
> housing 
> tightly. If it does not, you'll get a messy creek of fast hardening
> epoxy pouring 
> from under it.
> 
> 8. Now set the headlight vertically so that the tab points up. Shim
> it up and 
> secure it from falling on the floor.
> 
> 9. Prepare yet another portion of the fast drying epoxy. Make it at
> least 4x as 
> large in volume.
> 
> 10. Carefully pour the epoxy into the cavity between the tab, the
> housing and the 
> masking tape on both sides. Be sure not to reach the metal speed nut
> for the 
> mounting screw.
> 
> 11. After the epoxy hardens a bit, remove the masking tape. Let it
> harden completely.
> 
> 12. Reinstall the headlight. You'd notice that the newly repaired tab
> is hard as a 
> rock if you compare it to the intact one on the other side. For some
> reason Audi 
> had decided to make the top mounting tabs flimsy and to act as a
> spring. Perhaps 
> there was a reason behind this. However in my book a hard as a stone
> repaired 
> mounting tab sure beats the broken one.
> 
> -- 
> Igor Kessel
> http://home.comcast.net/~KBATPO/
> 
> _______________________________________________
> S-CAR-List mailing list
> S-CAR-List at audifans.com
> http://www.audifans.com/mailman/listinfo/s-car-list
> 



		
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