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    
FocusFest Ford Focus Tire & Wheels FocusFanatics Merchandise

 
 
Thread Tools Display Modes
Prev Previous Post   Next Post Next
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
 

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 10:36 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.