How to Fix a Broken Fog Light Plastic Bracket

How to how to repair a broken bracket on your fog light, this can also be applied to your headlights as well. All new vehicles have a plastic framework that bolts to the vehicle. Unfortunately when the light experiences some form of impact, there is the risk of the mounting brackets breaking. Purchasing a light replacement can be expensive, either used or new. With a broken mounting bracket, your light may vibrate causing your beam to bounce and this also affects the aim of the light which will decrease your lighting performance at night. #budgetrepairs #howto #autorepair

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Tools/Supplies Needed:
-heat gun
-wax and grease remover
-isopropyl alcohol
-plastic expoxy
-sandpaper
-wirebrush

Chapters:
00:00 Intro
00:29 Light Removal
01:00 Light Cleaning/Prep
01:29 Soldering Plastic
02:08 Applying Epoxy
02:50 Installation

Procedure:
It’s best to remove the light so it has full access to the broken component. Removal procedures will vary. You’ll most likely need to disconnect the light bulb or electrical harness. Then finish by unbolting the light.

Using a wire brush, this light is excessively dirty so I removed any hard debris with this. 

Use a wax and grease remover to clean the plastic and remove any contaminants that may cause adhesion issues. Don’t use a brake cleaner as we will be heating up the plastic in a moment.

Next was cleaning up the break with sandpaper to remove any debris. 

This time around I used rubbing alcohol to clean the plastic.

Hold the broken component in place and then using a solder iron with a flat tip, melt along the crack going deep into the plastic. You’ll need to mold the plastic back and forth in order to keep it smooth and fill in the crack. You’ll need to do this on both sides. The side that mounts to the bumper bracket, I am trying to keep this as smooth as possible so it doesn’t throw out the light adjustment.

Once done, here’s what it currently looks like. I have found soldering plastic like this can be strong but just to be sure, I’m going to take extra precautions.

Next the plastic is given a light sand to scuff up the surface for adhesion.

Again decontaminate the area with rubbing alcohol.

Here I have an automotive grade two part plastic epoxy. This will need to be mixed and applied to one side of the bracket. It is best to apply it on the side where it doesn’t affect the adjustment of the light beam. This is self-levelling so it will smooth it out to some extent.

Once done, place it off to the side where it can dry. Depending on what type of epoxy is used, this may take anywhere from 12 to 48 hours to fully harden.

Now here’s a view before it’s installed.

Next the light is installed back into the vehicle. Depending on how the repair went, you may or may not need to slightly adjust the aim of the light. Both fog lights and headlights can be aimed. For this truck, the outer bezel needs to be removed and behind this will be adjustment screws for up-and-down movement and left or right movement. 

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