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-   -   Repair of Cracked Mach HID Headlights (Lot's of pictures) (http://www.focusfanatics.com/forum/showthread.php?t=271775)

bay_wolf 10-29-2011 10:07 PM

Repair of Cracked Mach HID Headlights (Lot's of pictures)
 
Background:
I picked up a set of Mach HID headlights for $50 which had been in an accident so that the bottom corner of the Driver side was cracked pretty bad and did not come with ballast, bulb, or ignitor. It did come with the Depo branded projectors which I've heard are better then the original ones but I don't know for sure. Here are a few pictures:

http://i.imgur.com/tW3Z1l.jpg

http://i.imgur.com/dImXBl.jpg

http://i.imgur.com/1WPYZl.jpg

http://i.imgur.com/kWiY1l.jpg


Process:
I read up on how to repair headlight plastics and found out most, including these, are made of Polypropylene which is a thermoplastic meaning the epoxy type stuff won't hold onto it. So, I found out that if you melt the plastic together then it will hold as a repair. I just used a soldering iron to melt the plastic and used a dvd case as "solder" when needed. The important part of using the dvd case was it polypropylene also and mixed together well with the melted headlight housing. Here's a youtube video on the process:
YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.



Pictures:

http://i.imgur.com/4Zenul.jpg
I repaired the crack on the bottom first

http://i.imgur.com/5rVjBl.jpg
http://i.imgur.com/q7nQSl.jpg
Next was the hole in the bottom where plastic was missing. The liquid is water I was using to test to make sure none could get through.

http://i.imgur.com/glXRUl.jpg

http://i.imgur.com/ZFgZFl.jpg
The edge of the headlight I had spot welded and beginning to repair.

http://i.imgur.com/Z5Kf5l.jpg
Doesn't look the best but is solid. The corner was split into 3 pieces that had broken off when I removed the lenses so I had a lot of repair I had to do in this area. I reinforced it with the dvd case by mixing the melted plastic.


Repair Complete:

http://i.imgur.com/pI4d5l.jpg

http://i.imgur.com/WCijTl.jpg

http://i.imgur.com/sxHrml.jpg

http://i.imgur.com/itC24l.jpg

http://i.imgur.com/XyTxSl.jpg

Next Stage (stuff I'll be posting about later in this thread):
  • Repair the tabs that are broken by plastic welding and reinforcing them with metal.
  • I've purchase an aftermarket D2S HID kit from DDM Tuning (35w 4500k) and will be wiring it up to the Mach's.
  • Wire up the connector to the factory wiring on the car.
  • Buff up the lenses and install Lamin-x.


Questions:

Should I paint the inserts all black like this:
http://i172.photobucket.com/albums/w...c/b735b930.jpg

Or should I paint them black except the rings around the lights like this:
http://www.focusfanatics.com/gallery.../12785hed1.jpg

Or should I leave them chrome (my focus is a white wagon)?

Useful-idiot_mike 10-29-2011 10:23 PM

nice right up! i did the same to my lights about month ago but i didnt paint i just used bleach to take off the chrome(imo alot easier!!), it left a shiny black plastic that looks GREAT!! i didnt do the rings but i kinda like the all blacked out look i got with mine. heres some pics of them on my car to maybe help ya decide!! not trying to jack your thread!!
http://i290.photobucket.com/albums/l...s/IMAG0058.jpg
http://i290.photobucket.com/albums/l...s/IMAG0060.jpg

bay_wolf 10-29-2011 10:34 PM

Quote:

Originally Posted by Useful-idiot_mike (Post 3874929)
nice right up! i did the same to my lights about month ago but i didnt paint i just used bleach to take off the chrome(imo alot easier!!), it left a shiny black plastic that looks GREAT!! i didnt do the rings but i kinda like the all blacked out look i got with mine. heres some pics of them on my car to maybe help ya decide!! not trying to jack your thread!!

I actually kept track of your thread and will end up using bleach to change them to black if I go that route with them. I'll probably try to mask off the rings first and see how I like it with the rings chrome and the rest black.

ViperThreat 10-29-2011 11:06 PM

color-match the rings. go white :-P

bay_wolf 10-29-2011 11:07 PM

Quote:

Originally Posted by ViperThreat (Post 3874971)
color-match the rings. go white :-P

I've thought about this option as well but don't have any pictures to go on and see if it looks good. Also, makes selling them at a later date harder (not that I plan too but who knows).

UtahSVT 10-29-2011 11:22 PM

The picture of the lights with the chrome rings is my old car! I have done probably like 6 sets of Machs now and I have done variations with the rings every time. In my opinion the headlight loses some of its "character" when it is all blacked out, the rings help it maintain some "definition".

bay_wolf 10-29-2011 11:35 PM

Quote:

Originally Posted by UtahSVT (Post 3874984)
The picture of the lights with the chrome rings is my old car! I have done probably like 6 sets of Machs now and I have done variations with the rings every time. In my opinion the headlight loses some of its "character" when it is all blacked out, the rings help it maintain some "definition".

Yep, sorry for taking your picture but it was the only one I've ever seen done that way. I'm leaning heavily into doing it as it knocks the chrome bling down but keeps the definition like you said.

bay_wolf 11-13-2011 09:35 PM

Here's a sneak peek:
http://i.imgur.com/BuftAl.jpg
http://i.imgur.com/2Yjyal.jpg

Body color matched rings with the rest being black.

SvviftSVT 02-12-2012 09:02 PM

i know this is old, but looks sweet.

rambleon84 02-13-2012 11:34 AM

Well since this has been bumped already, any updates bay_wolf?


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