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1989 300e; 1983 240d
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18 Posts
Discussion Starter · #1 ·
Greetings,

Last year I acquired a very nice '89 300e (pre-facelift) that is a USA model with the horrendous DOT-mandated headlights. One of my cosmetic projects was to install cleaner looking Euro Headlights. After doing a bit of research, I determined scoring OEM Bosch/Hella units would be optimal in terms of fit (apart from keeping it as original as possible).

I found someone in Europe on a w124 FB forum who had new Hellas, and I pulled the plug and bought them. They are very nice new units, but during transit a small part of the right headlight lens frame bracket cracked. (Where the 8mm bolt goes through to hold the metal trim below the headlight.

My question is what to do?

(1) My US DOT spec headlights are in perfect condition. Would it be possible to use that headlight frame?

(2) I think I may be able to use a strong adhesive to put the pieces together? I don't think that makes sense?

(3) Do I need to find new headlight lenses/frames due to this bracket being broken?

Other thoughts?
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06'E350 wgn,05'E320 CDI,04'E320 wgn,85'300CD,67'230SL
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450 Posts
The Euro lights look so much cleaner. IMHO It would be worth a multi-step J-B weld. Maybe put all the small pieces together, and then adhere them together onto the frame.
I had a BMW motorcycle fairing that broke away at the mounting brackets. I added some pieces of steel wool into the wad of J-B and it's never separated since. Even if it's not quite perfect, you can file or Dremel off the excess to reshape. It's worth a shot! Bruno Sacco would approve. ;)
 

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W163 and General M Gremlin
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7,367 Posts
Th broken/cracked ear(s) - keep all the parts.
Dry run the pieces to fit, then..
sprinkle baking soda onto th cracks, etc and squeeze a few drops of CA onto it to (instant) bond.
It'll be good as new.
 
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