Today I’m off work so I’m finishing up the repair on a 40 autocycle light housing. The base metal was cracked in two places around the front screw. I built a custom clamp to hold the pot metal housing together and then fiberglassed the underneath where it will be an invisible strong repair.
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The first pic shows the cracks, next I applied the epoxy repair underneath and let it dry 2 days before working it down.
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Here is the final product. The cracks were filled in with epoxy and chrome painted to more or less match the base metal, it’s not perfect, but very strong and if you don’t stare at it looks convincing.
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The final detail is setting the plastic lens into the housing grooves. I used a little clear silicone to hold the lens and allow for some flexing. Now I’m sanding the lens just a bit so it conforms to the fender nicely.
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Final product!
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