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How to fix a hole in Headlight Assembly????

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  #11  
Old 01-20-2011 | 03:42 PM
novavon's Avatar
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Originally Posted by yloDiscoII
Damn...they look so similar...you SURE? Thanks Cam.

This would have been a good time to "upgrade" to the 03/04 style lights if I wasn't about to drop so much $$$ on lift/tires.
I've actually done the headlight conversion and while it does indeed look great, it isn't perfect. Other people think they are on properly but YOU will always know that they aren't

I still do have a pair of the old lights that I may sell if you're interested?

Basically, 98-02 lights (glass) not the 03-04 ones. PM me?
 
  #12  
Old 01-21-2011 | 10:26 AM
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Originally Posted by novavon
I've actually done the headlight conversion and while it does indeed look great, it isn't perfect. Other people think they are on properly but YOU will always know that they aren't

I still do have a pair of the old lights that I may sell if you're interested?

Basically, 98-02 lights (glass) not the 03-04 ones. PM me?
PM Sent
 
  #13  
Old 01-21-2011 | 12:45 PM
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What kinda bulbs you run in the conversion? HID Xenon? Those look bad ***....
 
  #14  
Old 01-25-2011 | 03:37 PM
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As suggested above, I'm going to try some epoxy to plug the hole, then drill a small drain hole so water can get out if it gets in...

Thanks everyone for the input.
 
  #15  
Old 05-05-2011 | 05:57 PM
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Default epoxy works, but it ain't pretty

3.5 month update....if anyone gives a hoot

The epoxy I used on the headlight assembly turned to a yellowish-brown tint (due to the heat?), but has held water out pretty well, still get some condensation on the insides during really wet days, but at least there is no sitting water inside the assembly causing my headlight bulbs to explode like before.

Good, cheap, temporary fix.
 
  #16  
Old 05-05-2011 | 08:24 PM
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You can also go a hobby store called hobbytown USA. They sell clear plastic sheets. You could make a template and cut out the piece your missing. Then you can use clear epoxy to seal it. Then you can sand and polish it with fine grain sand papers and rubbing compound.
 
  #17  
Old 05-05-2011 | 11:24 PM
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Originally Posted by DiscoRover007
You can also go a hobby store called hobbytown USA. They sell clear plastic sheets. You could make a template and cut out the piece your missing. Then you can use clear epoxy to seal it. Then you can sand and polish it with fine grain sand papers and rubbing compound.
Yeah, I considered that also, but seeing as the hole wasn't that big I thought the epoxy would do the trick. So far it's worked as good as I hoped it would (no more water sloshing around in the assembly) just ugly since it yellowed.....not that I have anything against things that are yellow
 
  #18  
Old 05-06-2011 | 08:30 AM
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Originally Posted by yloDiscoII
Got a rock straight through my headlight a couple weeks ago, and with the glorious non-stop wet weather we've had up here in Seattle, I've got water and/or condensation in the light 24/7. Finally yesterday, the bulb (literally) exploded.

I am planning on tackling this over the weekend and wanted to see if anyone had any luck sealing an eraser sized hole in a headlight assembly? Any ideas or things to try are welcome.
Consider buying a clean used light assembly for around $45.
 
  #19  
Old 05-06-2011 | 01:49 PM
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Originally Posted by Disco Mike
Consider buying a clean used light assembly for around $45.
That will be indeed the ultimate solution, just playing hardball with a local wrecking yard to get the price down
 
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