Weekend Project: So...in light of my New French Yellow bulbs decided to restore my broken salvage Headlight door
Buy: JB Weld Clear ($5.99 at home depot) to glue a 30 degree of plastic ring at t 10-1
http://www.homedepot.com/p/J-B-Weld-25-ml-ClearWeld-Quick-Set-Epoxy-Syringe-50112/204986141I. Wash -You can unscrew all the electric sockets, boards, and wires and just have the metal/plastic frame.
-Put plastic in bottom of sink and spray with scalding hot water and dish-was liquid, and soak; dissolves grime, dirt, yellow baked on film.
-The plastic will flex and metal will expand a bit and lens just slips out, no pressure at all.
-Next, scrub inside of lens with toothbrush, or plastic scrub (not steel wool); dry and leave in sun.
Note - If plastic is opaque, has yellowing, rust stains, fogging, cloudiness, etc; dilute below in gallon solution of water:
-Soak in bucket filed with solution of 2 Cups White Vinegar overnight
-Soak in bucket with 16oz bottle of 3% Hydrogen Peroxide for 4 hours; wash off, leave in sunlight for 4 hours (UV will activate)
-Soak in bucket with 1 Cup of Bleach for 4 hours; wash off.
-For deep staining: use Baking Soda powder to make paste; an old tooth-brush to gently scrub plastic inside and out (pre/test on covered edge to make sure doesnt mar surface).
If all of above fails use Bug & Tar Remover to coat outside and inside of lens and wash off promptly (Rain-X Gel or Tarminator). This will strip plastic of all contaminants and make clear.
II.Polish Polish outside and INSIDE of lens with Mothers Plastic Polish, Meguiars, #10, or#17, or Novus 1-2-3.
Inside lens needs extra attention to get polish out of all ribs (flat screw driver in cloth)
Do 3 applications and let dry to haze then polish firmly on thick towel.
Note: Novus # 3 is especially good for deep scratches and road rash.
III. Glue:-Clean off broken pieces with alcohol, sand edge with emory board or fine sand paper
-Mix epoxy, and after 4 min, dip a bead on each end of broken piece (works best gluing one side only)
-Position and hold for 10 min, so you have perfect arc.
-Use a pin or thin nail to get a bead coat small fillet in edge; and coat small square layer on underside (not too heavy).
-Put in sun to dry for 1 hour (UV helps activation), should feel tacky; will dry cyrstal clear and give almost a fused look to plastic
-Cures overnight and smooth to touch.
IV. Re-assemble-Check the glued areas; should be hard.
-Position the TOP of plastic ring in
first; there is a bevel edge that must fit into chrome ring top,and clear tab.
-Next, pull at middle of chrome ring a bit, to snap in middle plastic tabs.
-Note epoxy is flexible and you can see some flex while fitting.
-Finally, go to sink and run scalding water, on lower half of plastic lens and chrome ring for 2-3 minutes.
-Check top is still seated; then gently snap one corner in at a time; if you hear scrape sound; its not hot enough.
-Once one corner is in , the top edge might protrude a bit/askew.
-Re-heat other corner 2-3 minutes and it will pop in; use damp towel for leverage (DONT push down plastic on hard edge.)
-Plastic at top will be seated, flush.
-Leave in sun to dry and will cool to fit.
Easy 1-2 hour project; if your lens are cracked or not crystal clear, you should do this for cost of soap & water, $6 Polish, and $6 glue.
PS, I sent the Fog reflector out to be re-silvered/plated for $75 (decided against re-doing the orange directional signal) as wires are soldered on and wire clips are very brittle, and dont want to risk breakage and MOT / DMV inspection issue.
