3SGuide

This is just a quick guide on how to fix the headlight bracket mounts, located on the lower portion of the headlight housing. This guide assumes you have the broken or cracked pieces.

Supplies you’ll need:

• Rubbing alcohol for cleaning
• Q-tips
• Paper towels
• Sandpaper (I used scrap bits of 400 grit)
• Loctite Plastic Epoxy (Home Depot)
• Some small paintbrushes
• Rubber bands and/or clamps

Following the Plastic Epoxy instructions, you’ll want to thoroughly clean all sides of the broken piece and the edges of the hole in the headlight housing. Use alcohol and paper towels (Q-tips for the hard-to-reach areas). After everything is clean, test fit the broken or cracked piece into its original position to make sure it lines up. You may need to do a little sanding of the edges so that everything fits properly. Take your time doing this, it’s important so that everything lines up afterward. Lighly sand any interfaces between the broken parts and the headlight housing, it promotes adhesion. I recommend sanding a little outside the broken area so that you have some room to “anchor” the epoxy.

Open the epoxy per the instructions on the packaging and mix a quarter size amount in a plastic dish of some sort (doesn’t need to be anything fancy, I used the plastic that the epoxy came in). Mix it well and apply liberally to all sides of the affected pieces. The trick now is to either hold the piece there by hand (applying pressure) or use clamps and/or rubberbands to hold it in place. The product claims it sets in 5 mins, but I found that it needs more like 10-15. Feel free to make another pass of epoxy after you’ve clamped it down just to ensure every nook and cranny has epoxy in it. Here’s what the final product looks like:

Nothing pleasant looking, but it’s functional and sturdy if prep’d properly. Allow the parts to dry for 24 hours before re-installing the brackets.

If you have a hole in the housing but nothing to fill it with, try out JB Weld KwikPlastic (Home Depot). It’s a putty made for plastics that hardens to a sandable, paintable finish. Again, it’s not going to look that great, but it’s better than a hole!