Rods77

I need to repair a crack in my 77 headlight assembly, I don't think it's pot metal or aluminum....any answers? I want to reinforce behind the crack with some metal and rivets and then braze the crack together. What kind of brazing rod might work, I've tried aluminum, solder, and a couple types of metal rods.

Jason Staley

well, I can't help with what material it is, since I thought it was an Aluminum allow. However, I did break off the mounting tabs when I was in a wreck and I fixed them by fabricating a small reinforcement aluminum piece and screw/bolted everything back together. Whole project costed about $10, which is ALOT better than buying a new set. Been on the car for about 2 yrs with no problems.

You probably don't have to worry about the braze step. I'd just pop rivet/bolt a reinforcement piece on and let it go. However, can't blame you for wanting to go the extra step. Good luck. :cheers:

jetech

How about a small fiberglass/epoxy resin repair instead of a metal patch. (it works on aircraft) :D

Twin_Turbo

I'm pretty sure it's aluminium, both the door & the support.

Marck


[Modified by Twin_Turbo, 2:38 PM 10/26/2002]

LAvetteman

Is it cracked where the headlight holder meets the lid? I have one that is cracked there, I see no repair but to replace.

Monkeywrench

They are cast aluminum..

Bullyj

They look like pot metal to me but I'm not sure.

GTR1999

Anyone know if there's a body filler on top of the cover-under the paint?
Thanks,
Gary

72GACRZR

I have Richard Prince's Restoration book and it says "Later 1973 and all 1974-1977 cars have bezels made from fiberglass. All bezels are painted body color." Is that the part you are referring to?

Twin_Turbo

Yes, there is some kind of filler on top. It's yellowish stuff. I've sandblasted mine and that was what was udner the paint.

Marck

mrvette

Both the horseshoe shaped frame and the door are of cast aluminum, they are TIG weldable, buddy of mine did my frames, but the doors are missing a piece and were unfixable....I have two good frames for sale if anyone needs them...

GENE

Rods77

It is cracked under the lid where the pivoting bracket bolt is at. I've thought about using fiberglass but there are so many different shapes to work around I'm not sure if I can get a good bond. I may see if I can find someone to tig weld it....I also don't want to shell out the cash for a new one....thanks for all the feedback.

paintdaddy

All three pieces are pot metal and it is almost impossible to weld those .If you do find some one to weld those ,they are good and they know it .They will charge you a small fortune. It is probably going to be cheaper and easier to find a good used set. :seeya :yesnod:

Twin_Turbo

Look at this: http://www.muggyweld.com/super1.html

paintdaddy

I think I saw that stuff at a car show last year,and it worked well. :yesnod: :seeya