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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!

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Old 05-07-2013, 09:12 AM   #1
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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...
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Old 05-11-2013, 06:27 PM   #2
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Join Date: Sep 2004
Location: the OC
Posts: 32,472
My Ride: '06 AW 330ci
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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
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