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

[chris chambers]

OK so the pics got out of order in the first attempt!

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¤t=brokentabrearMedium.jpg

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


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



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