Fixing the headlight switch mounting problem

someotherguy said:

I used short-cut pieces of drinking straw as forms, so that I could build up little cylinders of Devcon Plastic Welder glue. That stuff sets quickly, but doesn't get brittle. I laid the switch on top and installed the screws, and let the glue set around them. Crazy strong.

All 4 pretty much completely broken off

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Drinking straw pieces cut to size

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Filled up with glue, switch and screws installed. And yeah it's a little crooked; I was super tired and got in a hurry.

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Interested in seeing your method too; it's an all-too-common damage area on the 88-94's.

Richard

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FerrariGuy said:

Just thought I'd add to this. I designed up a replacement bracket in Fusion and had it 3D printed in Nylon with an MJF printer (though I'm sure FDM would work as well). The part requires that the fragile original post be cut off and ground flush, then the new bracket can be superglued in. The file is here: https://www.thingiverse.com/thing:5833056

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someotherguy said:

Yep, but that specific product is the only one I trust. Devcon Plastic Welder. I've used it in places I really didn't expect it to hold, like the screw bosses for cable-operated vent controls on an old BMW - lots of pressure put on some tiny screws. Also used it to reinforce some cracks in the defrost vent area across the middle of a 1995-1998 style dashboard in a super rough-riding 3500HD. Not many products I consider to be near magic, but this is one of 'em.

Richard

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