Author Topic: 65-66 Headlight bucket repair? (Read 2511 times)

RyanG85 · « **on:** December, 27, 2009, 05:54:53 PM »

Both my headlight buckets have the common break on the top inside corner. I've seen kits like this one... http://www.calmuscleparts.com/store/1965-66-MUSTANG-HEADLIGHT-BUCKET-REPAIR-KIT-P29693C284.aspx
Is that kit recommended or is there a better option short of replacing the whole bucket?

daveSanborn · « **Reply #1 on:** December, 28, 2009, 07:46:52 AM »

I don't have an answer for your question, but thanks for posting that link. I didn't realize that kit existed and both of my headlight buckets are broken in that same spot. As a result of which my headlight bucket "doors" aren't aligning very well with the body line on the front of the fenders. Barring actual replacement of the buckets, it seems that trying to fix the existing buckets with the kit would be a lot easier. Any replacement bucket would have to be painted to match the rest of the car.

66gt350 · « **Reply #2 on:** December, 28, 2009, 07:51:55 AM »

That kit looks pretty cool. I'm just curious how well they work, and what type of epoxy you adhere the tabs with. I may have to order some to test it out.

-rob

RyanG85 · « **Reply #3 on:** December, 28, 2009, 07:58:30 AM »

There is a cheaper kit on ebay that comes with JB Weld to attach the piece. If I get the kit, I'll be using body panel adhesive to apply the parts. I thought I read somewhere a while back on another way to repair these, been a while so I dont remember where.

Havok1 · « **Reply #4 on:** December, 28, 2009, 09:16:15 AM »

I'm pretty sure that Mustang Monthly did an article on using the repair kit. I'm on my phone now, but I'll look for a link when I get home.

Fast68back · « **Reply #5 on:** December, 28, 2009, 10:45:38 AM »

The link Ryan posted says its JB weld. Seems kinda pricey for two pieces of metal and a pack of JB weld.

RyanG85 · « **Reply #6 on:** December, 28, 2009, 01:11:00 PM »

I agree, I was looking at my buckets which are off and stripped, thinking of bending up my own piece of metal and using body panel adhesive.

Here is the kit from ebay, shows a picture of it in place...
http://cgi.ebay.com/ebaymotors/1965-66-Mustang-Headlight-Bucket-Repair-Kit-Saves_W0QQitemZ220530832955QQcmdZViewItemQQptZMotors_Car_Truck_Parts_Accessories?hash=item3358a9763b

daveSanborn · « **Reply #7 on:** December, 28, 2009, 03:58:45 PM »

Along with a good body panel adhesive, would a few well placed rivets help fasten the bracket onto the bucket?

AzPete · « **Reply #8 on:** December, 28, 2009, 04:07:41 PM »

If you make a plate like the ones pictured with the JB Weld, you should be ok. I would drill for a couple of pop rivets, then mix the JB Weld (I prefer the JB Quick for faster setting) and smear it between the two pieces. Pop rivet it in place and then feather the edges with a bit more JB Weld. Do not forget the surface prep. Don't rush the set time and be sure to mix it proper.

My Dad and I have repaired many mixed metal type items in this manner and never had problems.....

RyanG85 · « **Reply #9 on:** December, 28, 2009, 05:00:35 PM »

The one on the ebay ad looks as if it has a dimples where it should be drilled.

napaguy · « **Reply #10 on:** December, 28, 2009, 08:05:57 PM »

mustang monthly did do a write up on the jb weld type repair and it seemed like an ok solution to a common problem. I bought reproductions and the quality was absolutely terrible. I ended up sending them back and finding originals that werent cracked. This took months of searching and a good size hit in the pocketbook though. One other thing to consider...I was talking to a mustang restoration guy and he said they use a sheet metal screw to attach that area...the details are really foggy but he said they did this on all resto's they performed. I am thinking he said to drill a small hole and run the screw upwards? HTH

RyanG85 · « **Reply #11 on:** December, 28, 2009, 09:08:14 PM »

I think the sheet metal screw is the repair I read about somewhere else. Not sure how it was done but seemed like a good solution. I've pretty much lost faith in repop parts, especially ones that are crucial to body fitment.

gotstang · « **Reply #12 on:** December, 29, 2009, 10:09:49 AM »

Quote from: daveSanborn on December, 28, 2009, 03:58:45 PM

Along with a good body panel adhesive, would a few well placed rivets help fasten the bracket onto the bucket?

I bought some aircraft-grade panel epoxy one time and it said only to use rivets to hold it down while it dried. It specifically mentioned that you didn't need rivets...I know one thing, that is some STRONG sh*t, I drilled and tapped a piece of the leftover stuff for the heck of it and it acted pretty much like you were drilling into steel. :ecit

RyanG85 · « **Reply #13 on:** December, 29, 2009, 10:37:47 AM »

This is my other thought... See in the picture, just below the crack, I'm thinking of running a sheet metal screw upward into the fender. I think this may be what I've read about before and what Napaguy was referring too. A short screw or maybe two should lock the bucket into place.

Thoughts???

daveSanborn · « **Reply #14 on:** December, 29, 2009, 10:47:12 AM »

It looks to be the simpler method of accomplishing the same result.

All this talk of headlight buckets is motivating me to go out this weekend and mess around with mine some. I'm really not happy with the fender to headlight door bodyline.

Also, I have some brand new still in the wrapper headlight adjuster screws/hardware that I've been meaning to install.

RyanG85 · « **Reply #15 on:** December, 29, 2009, 11:08:40 AM »

Glad I could get you motivated! I know what your talking about with the headlight door not lining up with that crack there :po. Would be nice if you could test out this screw idea and give some feedback.

napaguy · « **Reply #16 on:** December, 29, 2009, 03:44:28 PM »

Ryan and others,
The mans name is Harland Lippold and his business is horse heaven. His email adress is HorseHeavn@aol.com

He can be slow but will get back to you via email. He should be able to give you a more thorough description of what they do.

I also got to thinking that sluggo should have something to add to this being that hes a body guy and has probably faaced this before. HTH

hivewax · « **Reply #17 on:** December, 31, 2009, 01:47:29 PM »

i have a crack around that same location. i might try welding the pot metal and see what happens.

daveSanborn · « **Reply #18 on:** December, 31, 2009, 02:54:34 PM »

Quote from: hivewax on December, 31, 2009, 01:47:29 PM

i have a crack around that same location. i might try welding the pot metal and see what happens.

Good luck with that.... pot metal doesn't usually weld very well. I equate it to cast aluminum.

66gt350 · « **Reply #19 on:** December, 31, 2009, 03:09:53 PM »

I've heard that it don't weld worth a darn, but what about brazing using like a brass rod or even doing some silver soldering to fix 'em? both my headlight buckets have had that piece totally broken off, so I'm stuck with either the jb weld solution or new re-poop pieces.

AzPete · « **Reply #20 on:** December, 31, 2009, 03:14:16 PM »

My Dad was a pro at welding pot metal. I never developed the touch for it.... He always had a special rod and used an old arc welder. I saw tools he repaired last better than 10 years so I know it can be done.

Tony R · « **Reply #21 on:** December, 31, 2009, 03:20:25 PM »

When I pulled mine apart it had a screw installed like ryanG85 talked about. I haven't tried to fix mine yet but couldn't you TIG weld them. I have TIG welded cast aluminum many times with good results.

daveSanborn · « **Reply #22 on:** December, 31, 2009, 03:27:03 PM »

I believe that TIG welding is your best option.

guruatbol · « **Reply #23 on:** December, 31, 2009, 04:14:04 PM »

Quote from: 66gt350 on December, 31, 2009, 03:09:53 PM

I've heard that it don't weld worth a darn, but what about brazing using like a brass rod or even doing some silver soldering to fix 'em? both my headlight buckets have had that piece totally broken off, so I'm stuck with either the jb weld solution or new re-poop pieces.

I got some good ones from ebay for the 67. I found that trying to fix the pot metal was not happening.

I looked into the repops, but then I found some good ones on VMF and they had them on ebay too, so I got them from the ebay add.

Mel