Repair of Cracked Mach HID Headlights (Lot's of pictures) - Focus Fanatics
Ford Focus Forum
HomeContact UsAbout UsGalleryDiscussion ForumsMarketplace


Go Back   Focus Fanatics > Ford Focus First Generation > MK1 Focus

MK1 Focus The place to chat about general questions, window tinting, exterior body, interior and lighting upgrades for the first generation 2000-2007 Focus.

Search This Forum | Image Search | Advanced Search    
Ford Focus Tire & Wheels FocusFanatics Merchandise

Reply
 
Thread Tools Display Modes
Old 10-29-2011, 09:07 PM   #1
bay_wolf
Focus Enthusiast
 
Join Date: Oct 2010
Fan#: 79215
Location: Rolla, MO
What I Drive: 2002 White Wagon

Posts: 238
FF Reputation: 2 bay_wolf Good Standing Member
Buy-Sell-Trade Rating: (7)
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:










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:


I repaired the crack on the bottom first



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.




The edge of the headlight I had spot welded and beginning to repair.


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:











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:


Or should I paint them black except the rings around the lights like this:


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


__________________
Midwest Crew #64
bay_wolf is offline  
    Reply With Quote
Old 10-29-2011, 09:23 PM   #2
Useful-idiot_mike
Focus Enthusiast
 
Useful-idiot_mike's Avatar
 
Join Date: Sep 2011
Fan#: 89820
Location: wardensville, WV
What I Drive: 03 infra red svt#1537

Posts: 179
FF Reputation: 4 Useful-idiot_mike Good Standing Member
Buy-Sell-Trade Rating: (0)
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!!

__________________
2003 infra red svt #1537/ 00 honda cbr929rr/ 05 c230 kompressor
Useful-idiot_mike is offline  
    Reply With Quote
Old 10-29-2011, 09:34 PM   #3
bay_wolf
Focus Enthusiast
 
Join Date: Oct 2010
Fan#: 79215
Location: Rolla, MO
What I Drive: 2002 White Wagon

Posts: 238
FF Reputation: 2 bay_wolf Good Standing Member
Buy-Sell-Trade Rating: (7)
Quote:
Originally Posted by Useful-idiot_mike View Post
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.
__________________
Midwest Crew #64
bay_wolf is offline  
    Reply With Quote
Old 10-29-2011, 10:06 PM   #4
ViperThreat
Moderator OF DOOM
 
ViperThreat's Avatar
 
Join Date: Jun 2009
Fan#: 66026
Location: Concord, CA
What I Drive: '06 WRX Wagon 285whp/292wtq

Posts: 3,015
FF Reputation: 8 ViperThreat Good Standing Member
Buy-Sell-Trade Rating: (3)
color-match the rings. go white :-P
ViperThreat is offline  
    Reply With Quote
Old 10-29-2011, 10:07 PM   #5
bay_wolf
Focus Enthusiast
 
Join Date: Oct 2010
Fan#: 79215
Location: Rolla, MO
What I Drive: 2002 White Wagon

Posts: 238
FF Reputation: 2 bay_wolf Good Standing Member
Buy-Sell-Trade Rating: (7)
Quote:
Originally Posted by ViperThreat View Post
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).
__________________
Midwest Crew #64
bay_wolf is offline  
    Reply With Quote
Old 10-29-2011, 10:22 PM   #6
UtahSVT
Focus Addict
 
UtahSVT's Avatar
 
Join Date: Sep 2004
Fan#: 12785
Location: Utah, UT
What I Drive: '04 Black P-chrgd SVT ZX3

Posts: 1,031
FF Reputation: 1 UtahSVT Good Standing Member
Buy-Sell-Trade Rating: (23)
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".
__________________
July 2006 Ride of the Month
UtahSVT is offline  
    Reply With Quote
Old 10-29-2011, 10:35 PM   #7
bay_wolf
Focus Enthusiast
 
Join Date: Oct 2010
Fan#: 79215
Location: Rolla, MO
What I Drive: 2002 White Wagon

Posts: 238
FF Reputation: 2 bay_wolf Good Standing Member
Buy-Sell-Trade Rating: (7)
Quote:
Originally Posted by UtahSVT View Post
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.
__________________
Midwest Crew #64
bay_wolf is offline  
    Reply With Quote
Old 11-13-2011, 08:35 PM   #8
bay_wolf
Focus Enthusiast
 
Join Date: Oct 2010
Fan#: 79215
Location: Rolla, MO
What I Drive: 2002 White Wagon

Posts: 238
FF Reputation: 2 bay_wolf Good Standing Member
Buy-Sell-Trade Rating: (7)
Here's a sneak peek:



Body color matched rings with the rest being black.
__________________
Midwest Crew #64
bay_wolf is offline  
    Reply With Quote
Old 02-12-2012, 08:02 PM   #9
SvviftSVT
Release the Kraken!!
 
SvviftSVT's Avatar
 
Join Date: Aug 2008
Fan#: 58277
Location: Houston, TX
What I Drive: Green-Eyed 2004 Black SVT #0461

Posts: 15,212
FF Reputation: 10 SvviftSVT Great Standing Member
Buy-Sell-Trade Rating: (6)
i know this is old, but looks sweet.
__________________
TeamFOCALIZE!// HATCH NATION #45// October '12 ROTM

Track build will commence by Christmas (hopefully)
SvviftSVT is online now  
    Reply With Quote
Old 02-13-2012, 10:34 AM   #10
rambleon84
So mote be it
 
rambleon84's Avatar
 
Join Date: Nov 2007
Fan#: 51521
Location: columbus, OH
What I Drive: 2007 Dark Toreador Red ZX3

Posts: 5,253
FF Reputation: 23 rambleon84 Great Standing Member
Buy-Sell-Trade Rating: (14)
Well since this has been bumped already, any updates bay_wolf?
rambleon84 is online now  
    Reply With Quote
Reply

Bookmarks & Social Networks

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -5. The time now is 09:25 AM.


Copyright 2002-2014 FocusFanatics.com. All Rights Reserved : Terms of Use : Privacy Policy : Advertise Information : Site Map

Focus Fanatics Ford Focus Forum offers many fun ways for you to engage with other Ford Focus Owners from across the world. Whether it be about the aftermarket performance modifications, technical how-to's, European tuned suspension or awesome fuel economy similar to the Acura TLX or Fiesta ST. You can find all Ford Focus and Focus ST related information here. Join our Ford Focus discussion forums and chat with local Focus enthusiasts in your area.