Headlight SNAFU - Wrist Twisters
 
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post #1 of 15 Old 06-12-2012, 12:38 PM Thread Starter
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Headlight SNAFU

Went to go for a ride Sunday and caught this on the walkaround.

It's never been crashed, no major hits I'm aware of, and just looks like it decided to fail all by itself.

Working up a strategy for repair that will include a thin strip of stainless steel 2.5mm x 0.8mm (remnants of replacing Honda windshield wipers) bent to an appropriate shape, and heated and melted into the plastic to help hold the broken piece in place while the JB Weld cures and serve as a reinforcement.

Has anyone else had this happen? A quick search turned up nothing relevant.

Rob
Attached Images
File Type: jpg Headlight SNAFU 1.jpg (90.0 KB, 47 views)
File Type: jpg Headlight SNAFU 2.jpg (105.9 KB, 56 views)
File Type: jpg Headlight SNAFU 3.JPG (116.0 KB, 36 views)

If it has already been done, it is safe to assume it is possible to do it.
On the other hand, if it has not been done never assume it is impossible to do it.
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post #2 of 15 Old 06-12-2012, 01:32 PM
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Hmmm... Never seen that happen before but I'm sure when you get through with it it'll be as good as new!

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post #3 of 15 Old 06-12-2012, 01:50 PM
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I think you should just machine yourself a whole new bucket out of a chunk of billet....

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post #4 of 15 Old 06-12-2012, 02:02 PM Thread Starter
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Quote:
Originally Posted by hasbeenracer View Post
I think you should just machine yourself a whole new bucket out of a chunk of billet....
Great -- the $475 headlight bucket! That's just the stock.

Frankly, I'm considering taking a mold off the original and duplicating it in carbon fiber / kevlar / boron borided-tungsten fiber prepreg. I can get rem pieces of it for free, and brother would it be strong!

Don't hold your breath.

Rob

If it has already been done, it is safe to assume it is possible to do it.
On the other hand, if it has not been done never assume it is impossible to do it.
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post #5 of 15 Old 06-12-2012, 02:53 PM
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I had that piece break off but it was my own fault. I needed to replace my headlight bulb and was removing the trim ring. Forgot how it came off and tried to force it, without removing my windscreen. I just expoxy'd it back on and it seems to be holding just fine. I'm sure JB Weld will do the trick.

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post #6 of 15 Old 06-12-2012, 03:03 PM
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yup, happened to me,maybe 2 years ago.
I used some of that plastfix stuff. It is still holding

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post #7 of 15 Old 06-12-2012, 06:52 PM
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probably the vibes got to it.... how many miles on the bike?

either way.... my fix for stuff like this... 5 minute quick set clear epoxy.... and some fiberglass sheet to bridge the gap and make the hold MUCH stronger than just epoxy.

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post #8 of 15 Old 06-12-2012, 06:59 PM
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Sooo a headlight bucket is like...a million dollars or something?

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post #9 of 15 Old 06-12-2012, 07:23 PM
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Quote:
Originally Posted by marylandmike
I had that piece break off but it was my own fault. I needed to replace my headlight bulb and was removing the trim ring. Forgot how it came off and tried to force it, without removing my windscreen. I just expoxy'd it back on and it seems to be holding just fine. I'm sure JB Weld will do the trick.
Did the same thing. JB welded it back together and still holding strong.

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post #10 of 15 Old 06-12-2012, 09:12 PM Thread Starter
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Quote:
Originally Posted by Lemonhead View Post
Sooo a headlight bucket is like...a million dollars or something?
Might as well be. I'll take about 3 cents worth of epoxy and a little creativity any day.

Rob

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post #11 of 15 Old 06-12-2012, 09:44 PM
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That happened to me when I went to take my headlight off. Turns out the idiots that repaired the bike some time ago used a tube of JB weld to hold the headlight bracket together and didn't allow for the headlight trim ring to separate from the bucket-



So I ended up flush riveting a small tab of aluminum to the trim ring and match-drilled a hole to the bucket.



Now I have two allen bolts and a screw that hold my headlight in place instead of that tiny piece of plastic.

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post #12 of 15 Old 06-13-2012, 12:22 PM
just send it.
 
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^^ The carbon fiber in the last picture looks AWESOME!



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post #13 of 15 Old 06-13-2012, 11:39 PM
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My bike lost that too from the previous owner. He has used a small velcro piece there to hold them together and they are doing very well, the 2 side screws help keeping everything tight

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post #14 of 15 Old 06-20-2012, 10:45 AM Thread Starter
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Several obligations kept me from repairing it until Sunday -- and found out that a 2" strip of Gorilla tape holding the trim ring in place works quite nicely until the repair is done.

Annnny way, I finally got around to fixing it, and it took only 15 minutes plus the better part of a day for the epoxy to cure. Below is a picture of the stainless strips melted into the plastic with a soldering iron. Don't worry: I reheated the one on the left to increase engagement. No pictures of the epoxy -- all I did was to lay enough on and cover it with tape until it's cured.

Rob
Attached Images
File Type: jpg Headlight fix 1.jpg (146.9 KB, 30 views)

If it has already been done, it is safe to assume it is possible to do it.
On the other hand, if it has not been done never assume it is impossible to do it.
------- Rob --------
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post #15 of 15 Old 06-20-2012, 11:02 AM
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This should probably be a sticky.
I will do it to my headlight broken tab...

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