911Jetta

A couple weeks back I noticed my front passenger headlight assembly was loose and at night the headlamp beam pattern would bounce up and down just a bit. Last weekend I finally got around to seeing what the problem is....

After removing the headlamp ring I easily saw that two of the four tabs on the cast aluminum headlamp frame were broken! A quick search for a new assembly (964.199.490.50 009) showed that a replacement would cost $90. Not horrible I guess, but decided to see if a little MacGyver work could solve the problem?

I purchased some epoxy, metal wire and 1/16" X 3/4" flat aluminum and decided to rehabilitate the old assembly... Basically I cut, drilled, and shaped the aluminum strip until the broken side matched the original assembly shape. After a test fit in the fender bucket, I marked the correct position of the aluminum strips and glued everything into place. Somewhat unsure of the epoxy's strength, I decided to drill holes in the assembly and aluminum strips and tie the pieces together with picture frame hanging wire (plus more epoxy on the wire and through the holes).

It might look ugly... but it's hidden and feels very solid, plus saved $90+!
AND, it's a lot of fun playing MacGyver!

hawk911

if it works for ya; nice way to save $90.

Strega(UK)

You guys stateside certainly have odd looking headlamp asemblies!!

crg53

Does anyone have pictures of Euro (H4) headlight assembly c/w hardware, I am in the process of installing H4's, and find the mounting a little Mickey Mouse.

Thanks

911Jetta

I think H4s are detailed in the second row on the headlight diagram below... it think, as obviously I'm too cheap to ditch these glued-up H5s and get real headlights...

elbeee964

No swiss army knife? Or duct tape? - No gum wrapper?

- Fah!
MacGyver would'a made a working Carrera GT with only half the stuff you had at hand.


Slick job.

Rocket Rob

Creative solution, I like it. By the way, I will be upgrading to H4's over the winter. Let me know if you want some of my old headlight parts.

brad@tirerack.com

elbeee964

ian89C4

Good job on the fix!! Very creative, I like it.

And all these years I thought his multi-tool was his swiss army knife.......