3rd gen headlight tab reinforcement/repair

Designed up some repair tabs for a set of lights I picked up. Figured I would see how they work and then offer them for sale later.


They also should work to reinforce good tabs (so that they don't break).


The intent is to epoxy these to whatever remains of the existing tabs, reinforcing or repairing the light.

I have a couple sets I would like to get some feedback from others on, if anyone is willing to try some and let me know how they work I would appreciate it. I have two sets in red and one in black.

 

I think a plastic hot air "welding" gun would do better than epoxy. But not as accesible, really. What type of epoxy/glues are you looking at?

 

Although the parts are a pretty good fit I won't claim they are perfect. Best to have something with just a bit of thickness to it. I'm going to suggest the gorilla glue two part epoxy available at Lowes. Some thickness to it and readily accessable.

 

What type of plastic are the braces made of, and can you get a pic of the stamped/molded in material mark somewhere on the backside of the lamp? Then you can go to loc-tites site and use their adhesive selector. A rubber toughened cyanoacrolate is probably not a bad starting point, given the temperature ramge and cycling these will see, and vibration.

Looks like a solid fit-up from your pics man.

 

Do they fit morimotos?

 

Currently they are made from abs. I considered nylon however it's tendency to creep was less then desirable. Abs handles temps well and is reasonably impact resistant.

Good tip on the loc-tite site, I was not aware of that. Thank you

The fit is pretty decent, just not exact. I am working with 3d scanning now to create a more accurate fit and increase surface area. There are more steps to that however and it takes time to learn new tools and techniques.
Here is a 3d scan of an original tab done using Reality Capture (amazing software) and over 100 photos. This 3d shape will then be subtracted from a generic shape in order to create an exact fitment.

 

I expect not, they might however. Do you have a picture of the morimoto tab?

 

I can get one to you tomorrow.

 

Looks like the factory housing is polypropylene, a more difficult plastic to glue.

Digging into various solutions now

Edit
JB Weld 50133, Plastic Bonder, specifically states PP (Polypropylene) and ABS. That is the best bet

 

I'm kinda surprised its polypropylene, I was expecting some sort of glass reinforced nylon.

 

I was too

 

Can you send a pic of the Morimoto tab? I would be interested to see if it works for them as well

 

I can grab you a photo of Morimoto tabs if you still need them.

 

That would be great if you could.

I did look at the OEM LED lights and they use a slightly different tab so my current design won't work for them. I am looking at picking up a set though to make repair/reinforcement tabs for those as well.

I should have a batch of tabs to send to testers this weekend.

 

Props to you for R&D'ing these. eBay is flooded with nice headlamps that have busted tabs, way cheaper than buying them new.

Toyota sells (used to sell anyway) bolt-on tabs, to replace broken tabs for the headlamps on the 2nd gen Tacos...and it's never made sense to me why they haven't followed suit with the 3rd gen.

 

I have some more tab repair pieces I would be willing to send to testers in exchange for feedback and pictures.

 

I think all my sets have been claimed for the moment. Thanks

 

What about the side tab? Just found mine is broken, which now won’t allow the bumper clip to stay bolted down. Ugh.

 

The small one? I was seeing a bunch of lights with broken side tabs, I will have to add that to the kit. I should be able to do something for that spot.