headlight covers

[mpapa]

The plastic tabs at the top of my carello headlight covers on my 79 spider have broken off! Now, when I am going over 50 mph, the covers look like they are trying to tear themselves loose and fly over my windshield- really, I can see a 1" space at the top when I am driving at that speed. They are in great shape, otherwise- nice and clear. Has anyone else had this problem and come up with a fix? I don't think drilling a hole and attaching a screw is going to work. Any adhesives I should be thinking about using?
Thanks you guys for all your help in the past. Don't know what I would do without this forum.
Marco

[Farace]

I had one of the two tabs on one cover break off. I've been meaning to try, but haven't gotten around to it yet (those round tuits are hard to find), making a new tab from thin folded brass stock. I doubt I could adequately convey in words what I have in mind, but I'll try: The main "tab" part would be a bit of brass stock folded in half. At the point where the tab would attach to the cover, each side would take a ninety-degree turn away from each other (sort of forming a "T" shape) and then take another quick ninety-degree turn (now forming a sort of squared-off "Y" shape) where the distance between the two sides would now be a little less than the thickness of the plastic cover. If there was some space between the halves of the folded tab, then the tab would try to squeeze the plastic as it's inserted into the slot in the fender. Now, I know it would require more than that to stay attached, and this isn't entirely thought out (obviously), but those are the lines along which I'm thinking. I'm also considering attaching the brass with some tiny screws with some glue as added support.

Now all I need is the time to get around to trying this and finding what a folly it probably is.

[conedriver]

Hi Bob,

I have a whole collection of headlight bubbles, some with broken tabs, and your idea sounds like a good way to salvage a broken bubble. I wonder if your clip concept could be made of Aluminum or Stainless Steel for better appearance. Is this sketch what you have in mind?

Quote:

Originally Posted by Farace I had one of the two tabs on one cover break off. I've been meaning to try, but haven't gotten around to it yet (those round tuits are hard to find), making a new tab from thin folded brass stock. I doubt I could adequately convey in words what I have in mind, but I'll try: The main "tab" part would be a bit of brass stock folded in half. At the point where the tab would attach to the cover, each side would take a ninety-degree turn away from each other (sort of forming a "T" shape) and then take another quick ninety-degree turn (now forming a sort of squared-off "Y" shape) where the distance between the two sides would now be a little less than the thickness of the plastic cover. If there was some space between the halves of the folded tab, then the tab would try to squeeze the plastic as it's inserted into the slot in the fender. Now, I know it would require more than that to stay attached, and this isn't entirely thought out (obviously), but those are the lines along which I'm thinking. I'm also considering attaching the brass with some tiny screws with some glue as added support. Now all I need is the time to get around to trying this and finding what a folly it probably is.

[Farace]

George, I wish I could see the image, but I guess we've got something messed up with Excel on this computer. I'll try it at work tomorrow. But if my description made sense to you, then you've probably got a better idea than I do of what it should be!

[conedriver]

Bob, how about this?

Quote:

Originally Posted by Farace George, I wish I could see the image, but I guess we've got something messed up with Excel on this computer. I'll try it at work tomorrow. But if my description made sense to you, then you've probably got a better idea than I do of what it should be!

[Farace]

That's it, George, that's exactly what I had in mind. I'd also thought of one further bend in the clip edges, ninety degrees inward just a little, and carving a small groove on either side of the bubble near the edge, so that as the clip gets compressed, the additional little bend in the clip "grabs" the groove at the edge of the plastic.

[mpapa]

Bob and George
You guys are excellent. I think that will work. It seems like the broken tab is a common problem, although I think the cold weather in DC caused the plastic to become brittle- yes, I drive all year long. Think I will try some glue on the tab and see if it holds.
Thanks again you guys. I am sure there are others out there with the same problem. I can't tell you how frightening it was driving at 70 mph, looking over my hood and seeing the bubbles flopping around in the wind.

[Randal Harris]

FYI. I have repaired several headlight covers using banding strap material I got from the local hardware store. Many of their products (like lumber) come to the store held together with banding straps about 1/4 or 3/8 inch wide. The store gave me the scraps free. They are almost invisible (not for concours use however) and have not rusted yet. I did not use the "Y" approach, I kept one side straight bent the other side back on itself and when it got back to the headlight cover I bent it up at 90 degrees until it cleared the top of the cover the bent it back 90 degrees (I guess that it is kind of a "Y"). Then I placed it over the cover measured and cut the "cup" long enough to allow a pop rivet. Drill the hole for the pop rivet with the clip in the proper position on the cover. Attach the clip with the rivet and you are ready to install. BTW, you do have the plastic clips that are inserted into the fender and were designed to hold the tips on the headlight cover, don't you? International has had them in stock and they help keep the cover from banging around inside the slot in the fender.

Randy Harris
'63, "76 Spiders
'78 Sport Sedan