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Topic: How to make a new headlamp washer cover... (Read 3222 times) |
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Penguin
Full Member
Scorpio Owner 12/05 - 7/07
Posts: 188
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How to make a new headlamp washer cover...
« on: Feb 11th, 2007, 6:56pm » |
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I lost a headlamp washer cover in the bad weather last week and, having ascertained that you cannot buy these separately from the whole unit and wishing niether to shell out to replace something not broken nor have a hole in my front bumper, I have come up with a recipie for the following quickt fix, so if anyone else finds themselves with the same problem, here's what to do.
For this you will need:
- A pair of long-bladd sharp scissors.
- An old, black, VHS video tape box.
- Fine sandpaper.
- A stanley knife.
- Some of the (black) heavy duty velcro.
- A tube of evostick Mix and Fix.
- A piece of paper.
- A biro.
Method:
1) Get paper and biro and trace around the headlamp washer cover you still have.
2) Remove the inlay paper and the plastic cover from the video box and then cut off one face. (Obviously you can use another material for this but I used the video box because it's easy to cut and already black).
3) Cut out the tracing you made on the paper, TURN IT UPSIDE DOWN, (because you're making a cover for the other side of the car) and place this on the video box face.
4) Score around the tracing with the Stanley knife.
5) Cut out the shape you've just scored with the scissors (having scored it this should be easy).
5) (OPTIONAL) Take the sandpaper and smooth off the edges of what you've just cut out.
6) Take your new cover, the velcro, the stanley knife and and the Evo-stick down the car.
6) Place your new cover on the car and work out where it needs to be folded (this may possibly only apply to facelift cars, if not facelift covers are flat).
7) Score the fold line on the underside of the cover with the stanley knife.
 Fold the cover over until the desired angle is reached.
9) Place the cover back on the car and check that it does cover the hole, the fold angle is correct and it is not likely the catch on the underside of the light when elevating.
10) Take the velcro and cut out from the hard part only enough to cover the underside of your cover (except for outer edge which is meant to touch the bumper).
11) Also line the top of the unit with the hard edge of the velcro where you can (it's not even so just where you can is fine, don't block the jet). The reason for the velcro is because Evo Stick does not bond to video case material.
12) Mix up 3-4cc of your evo-stick and place it on the top of unit, taking care not the obscure the jet, make sure that you have enough so that the putty mound comes above the bumper hole.
13) Put your new cover in place.
14) Wait two hours...
15 ...and you're done.
There you go, quick and easy way to have yourself a new washer cover.
Cheers
Penguin
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scorpio_man
Administrator
Ford Kuga awd
Posts: 5654
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Re: How to make a new headlamp washer cover...
« Reply #1 on: Feb 11th, 2007, 9:23pm » |
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hi there
that's a good idea. any photos?
should help quite a few members. 
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Jonnycab
Senior Member
Former owner of 2.3 Ultima Facelift saloon
Posts: 3900
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Re: How to make a new headlamp washer cover...
« Reply #2 on: Feb 11th, 2007, 9:58pm » |
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Great idea, & very inventive 
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Kjetil S
Senior Member
2001 BMW 520iat
Posts: 1419
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Re: How to make a new headlamp washer cover...
« Reply #3 on: Feb 11th, 2007, 10:26pm » |
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You should probably throw together some pictures an make an article for the site
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http://uncyclopedia.org/wiki/Norway
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taliban aka Cheekyboy2
Senior Member
I'm a YaBB newbie!
Posts: 1552
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Re: How to make a new headlamp washer cover...
« Reply #4 on: Feb 12th, 2007, 4:40pm » |
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penguin, there was a thread on another topic board the other day about this; the video box is a good idea, i'd suggested carbon fibre sheet (available from motorbike shops), brushed steel/aluminium sheet or possibly titanium. then maybe use plastic trim (the type used on motorbike screens) to tidy up the edges if needed.
i looked at a facelift bumper yesterday at the herts meet and noticed it has a curve, this could be copied to pliable metal sheet using a edge gauge, the type of thing you use for marking out shapes on ceramic tiles etc.
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TiberiuS
Senior Member
Ex. 1996 2.3 Ultima - RIP P789 KHJ
Posts: 2257
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Re: How to make a new headlamp washer cover...
« Reply #5 on: Feb 12th, 2007, 5:55pm » |
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OR, plan B: rip out the headlamp washers altogether because they're a d**ned nuisance when you're driving along at 70mph with the headlamps on, use the screenwash and get a flood of murky water stream all over your nice clean polished bonnet  
Yes, I know...good use for old video boxes
Regards, Bruce
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Bruce - '07 Jaguar XKR coupe, '95 Jaguar XJ Sport 4.0, '82 Ford Capri 2.0 Ghia, '15 Honda Civic (sloooooww..)
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