Headlamp repair...Success

[WARATAP@aol.com]

I did it!  Remember the rule how when you first attempt a project on your car
to plan on it taking 2-3 times the time you would think --it still applies.

Now taking out the headlights isn't too difficult, once you get the hang of
it - but its still a PITA in the V8.  15 minutes (did it before to rinse out
inside haze accumulated through the years on inside of glass).

I was lucky enough to retract the glass chip inside the headlight intact.
 However, due to the chip beeing between Hi and Lo Beam reflectors, this
proved to be more involved, and requiring MUCH patience.  The glass would
have to be removed from the plastic reflector housing.  This is made more
difficult by a lip on the plastic, which neccessitates using either:  a)
sharp blade with 1/4" right angle at end (not easy- broke a few blades trying
to do the bend-should've preheated blade first)   b)  Strong Pick tool -
similar to the ones dentists/hygenists use.

So I broke a lot of this plastic surround trying; using razor blades, knives,
prying, etc.  Actually makes sense, when you realize how heavy the headlight
glass is.  Take breaks, otherwise you will break something (chipped the
headlight when first attempting to prise the glass from the bucket-ouch).  Be
very thorough.  The silicone they use is very tough!

Alas, after 2½ hours (including sanity breaks), I got the lens off.  Scrape
remaining silicone sealer from glass and bucket.  I cleaned inside reflectors
and headlamp glass with glass cleaner, being VERY careful with reflectors -
the chrome plating (on the plastic ones at least) is easily damaged/removed.

I mixed a small amount of the Devcon 5-minute clear epoxy dual piston plunger
(found at local hardware store under $4) for one minute as per istructions
and placed first into the chip recess caused by my prying first, and then
pressed the glass chip in place.  It's important to use this stuff sparingly
if you want to put the original glass chip back into place, as much of the
adhesive will be displaced.  It worked, so I next did the main chip.  Same
procedure, with a little seapage around corners (but it's inside the lens and
dries clear - didn't want to smear this stuff, although 3-M adhesive remover
seemed to do OK for removal while still wet.  Next I epoxied the broken
pieces of the retaining plastic of the housing before siliconing the
headlight glass to the bucket.  

While this was setting I flipped over the headlight glass so that the front
was facing up, and applied some expoxy to the small indent caused by the
stone so that it was even with headlight surface.

Since I was running very late for Graydons jazz/quattro get together in
Flint,  I took a chance and preheated the oven to 175º F ( expoxy is rated to
200º F) to speed-up the curing process (1½ hrs).  Total elapsed time,
including curing time and sanity breaks: 6½ hrs.  An you can only see it if
you're looking for it.  Now its time to put that headlight protection film
on.

Much thanks to Jim Dolan and Mike Arman for suggestions regarding this
repair.

HTH

-Ingo