If you recall, our fog lights (A4, S4, etc..) are held into the front bumper with two little round tabs that sit in a hole in the bumper (center of the car) and two screws that attach the fog light (outside of car).
The impact of the dog sheared the two tabs on my driver side fog light. They were a few months old.
I fixed them. How?
1) Find yourself some R/C Car nylon body posts from your local hobby shop. I used my good fog light as a reference to get the right diameter body posts. Purchase some two-part plastic welder/epoxy from your local hardware store. I found mine at Home Depot.
Tools required:
- utility knife
- plastic welder/epoxy
- R/C car nylon body posts
- cardboard
2) Sand down whatever remains of the existing tab with a nice fine metal file.
3) Cut to fit the nylon R/C car body post. I used my passenger fog light as a template to get the right length 'tab'.
4) Trim bottom of tab to conform to the rounded fog light housing on the broken fog light.
5) In a location with adequate ventilation, mix up the two-part Plastic welder/epoxy on a piece of old cardboard. Note: The welder/epoxy has some nasty fumes.
6) Spread the epoxy on the location of the tab on the broken fog light. The stuff I used sets up within a minute and is very, very durable (it eats Lexan as soon as it touches it).
7) Position new 'tab' accordingly.
8) Add more epoxy around the tab to create a 'fillet' of epoxy to help glue the tab onto the fog light. The theory here is that you're creating a flush glue joint that will be loaded up in shear when the fog light is in the car. Building up a 'fillet' helps reinforce the glue joint.
9) Move onto the second tab. Work within a 3minute timeframe so you can still position both tabs relative to each other and perpendicular to the fog light. Use the good fog light as a reference to get the 'tabs' in the right orientation.
10) Let the fog lights sit [overnight] for the glue to harden. Note: Its best to follow manufacturer's recommendation for permanent bonding before mounting the lights back onto the car.
11) Replace bulb if broken (mine was shattered)
This is a pretty strong glue joint. I pulled on the new tabs after them curing overnight and they didn't budge.
Here are photos of the finished product:
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Originally Posted by absolutegtr
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