Cracked lens repair project - E46Fanatics E46 BMW Social Directory E46 FAQ 3-Series Discussion Forums BMW Photo Gallery BMW 3-Series Technical Information E46 Fanatics - The Ultimate BMW Resource BMW Vendors General E46 Forum The Tire Rack's Tire Wheel Forum Forced Induction Forum The Off-Topic The E46 BMW Showroom For Sale, For Trade or Wanting to Buy

Go Back   E46Fanatics > Tuning & Tech > Lighting Forum

Lighting Forum
Angel Eyes, DDEs, lighted rings, Clear Turn Signals, LEDs, Xenon, HID, or Bi-Xenon. If it lights up and you want to discuss it, post here!

Thread Tools Search this Thread Rate Thread Display Modes
Old 05-07-2013, 09:12 AM   #1
Registered User
Join Date: Apr 2013
Location: Sydney
Posts: 7
My Ride: 330ci
Cracked lens repair project

I have a facelift coupe with OEM bi-Xenons. While repairing a headlamp washer leak recently, I noticed that a headlight lens is cracked. The crack starts underneath from where the clear lens meets the black housing, and extends forwards. Looks like a manufacturing defect, as the width and displacement of the two parts along the crack line suggest that they have been married unwillingly under some force.

There's no replacement lens offered either by BWM, or OEM suppliers like Magneti Marelli or Hella for this particular assembly. I've looked into the DEPO assemblies as possible replacements, but the OEM bulbs and ballast are not compatible. Replacement assemblies are ~$750 each, and I don't want someone else's used and possibly chipped (or cracked) lenses.

Long story short, the crack is not visible on the front of the lens yet, so I've decided that I've nothing to lose by attempting a repair. Did some research, and have determined that the lenses are made from a polycarbonate called Lexan, and that the best adhesive would therefore be an acrylic like Weld-on 16. I drilled tiny a hole just ahead of the crack to try to stop it extending any further, then glued it up. The bond looks strong, so I guess only time will tell now if this has worked...
Attached Thumbnails
Click image for larger version

Name:	Cracked lens.jpg
Views:	4644
Size:	98.3 KB
ID:	504368  
aristotle is offline   Reply With Quote
Old 05-11-2013, 06:27 PM   #2
Registered User
Join Date: Sep 2004
Location: the OC
Posts: 32,496
My Ride: '06 AW 330ci
Send a message via AIM to sillieidiot
that doesn't look like a manufacturing defect to me. but i guess your solution works. did you test it at all? like for water
I like to reply to threads with 0 posts

Have a lighting problem? Read this first:
Lighting-related Troubleshooting Guide
sillieidiot is offline   Reply With Quote

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Censor is ON

All times are GMT -5. The time now is 09:26 PM.

Powered by vBulletin® Version 3.8.8
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
(c) 1999 - VerticalScope Inc. All rights reserved.