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

Posts: 238
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Repair of Cracked Mach HID Headlights (Lot's of pictures)

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:

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.


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.


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
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