During my headlight retrofit I need bodywork advice

[KNG SNKE]

Bodywork is the main thing I have zero abilities in when working on a car.

Here is my issue. On the headlight bezel (clear plastic inside the headlight) there is a hole for the OEM level that sits in the headlight. I am removing this level on this spare headlight test bezel. I have tried to fill the hole with 1 minute epoxy and it would not bond to that bezel very well. I need advice on what to use to fill this hole. It is the size of a quarter. I need something to fill the hole that is not going to crack. See photo.

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[plumcrazy]

id try silicone or polyurethane, they shouldstick better to it

 

[KNG SNKE]

What silicone dries hard? I need to be able to sand it and paint it as well.

 

[plumcrazy]

oh, gotcha....

how about a poly urea ? just not sure it can be painted

 

[dave6666]

Those lenses are likely polycarbonate. What you probably will have to do is bond a piece to the back and use a filler material on the front. Search for info on bonding and repairing polycarbonate.

 

[JohnnyViper]

i would cut a piece of plexiglass a little larger than the hole then use Weld-On #4 Plexiglass Glue then back fill the hole and sand smooth, the #4 glue chemically combines and melts the two surfaces together into one. They use it in acrylic fish tanks to make a watertight seal

 

[JohnnyViper]

once the backing plexi is attached get another piece of plexi thats cut in the diameter of the hole and drop it into it with the #4 on the back and that will give you a solid surface, if you are going to paint the inside you can also use fiberglass resin to fill the hole

 

[KNG SNKE]

I cut a square of acrylic and super glued it to the back. I put another small piece of acrylic in the hole and superglued it to the back piece. I then filled it with JB weld. The bezel has to be painted on the outside to cover up that hole. Hopefully the JB weld does the trick.

 

[KNG SNKE]

just finished sanding the jb weld. Its holding good. Gotta do some smoothing because of air bubbles but it will work for what I need.