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Discussion Starter · #1 ·
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:


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)?
 

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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!!

 

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Discussion Starter · #3 ·
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.
 

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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".
 

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Discussion Starter · #7 ·
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.
 

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i know this is old, but looks sweet.
 

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Discussion Starter · #12 ·
Well since this has been bumped already, any updates bay_wolf?
Will have an update within a week. I've got the inserts painted finally (couldn't due to winter weather) and have one of the headlights rewired and working! Sorry for the insanely late bump but figured I'll be posting some update pictures soon.
 

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Discussion Starter · #13 ·
UPDATE:

It's been a while but the project was put on the back burner. I'm back to fixing them up and have gotten all of the electrical parts done. I am now on the stage of painting the inserts again as I've messed them up a few times. A great tip for anyone painting plastic is that the yellow can oven cleaner (high fumes and heavy duty) will remove paint off of the plastic without harming it. Just spray it on and let it sit for 24 hours. I'm hoping to have them painted by early next week. On to the pictures:

During my attempt to reinsert the projector into the housing I broke a metal part in half so I used some industrial strength Goop Adhesive to put it back together:



Here's some pictures of all the wires spliced, soldered, and routed around the case after installing the aftermarket HID kit:


This is a picture of the ballast attached to the bottom of the housing using velcro. The velcro is industrial strength and being held to the pieces using Goop Adhesive again since it's suppose to be one of the strongest glues.



Here's a final shot of both headlights without the inserts:
 

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Hey did you ever finish them and could you take a picture or two of the stock wiring harness to what you had to do to make it work?
 

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Discussion Starter · #17 ·
Hey did you ever finish them and could you take a picture or two of the stock wiring harness to what you had to do to make it work?
You'll never believe it with the thread being this old but I finally have them assembled! It took me forever to get around to painting the inserts but I've got them painted and the lenses put back on with sealant. I've got to use some sanding to restore the outer lens and solder in the new connections. I should have a few pictures up tomorrow and then the installation pictures sometime next week.
 

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Discussion Starter · #18 ·
Here's an update on pictures. I've still got to add a little more sealant for safety and then restore the lens on the headlights (3M kit with a drill to polish). And repair the mounting tabs along with wiring them in but it should go fairly quickly from here.

PICTURES
 

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Discussion Starter · #19 ·
Small update:

I've got both lenses restored (still a few scratches but not noticable enough) so the next step is to wire them up which will be done on Friday... Hopefully.
 

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Discussion Starter · #20 ·
FINISHED! (except to add some weatherstripping from my old headlights)

Pictures (Click to enlarge):




 
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