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Post Info TOPIC: Repairing broken headlight supports

Super Guru

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Posts: 8406
Repairing broken headlight supports

This is quite a common problem on TTRs and I have come across some ingenious repairs!

The blue headlight surrounds are hard to come by second hand so it is worth repairing them. 

I apologise in advance for the poor quality of the pics. I think I had the flash suppressed no

I carry a fairly heavy Slime compressor in a headlight bag on my TTR and, after a few spills, the brackets started to look a bit worse for the wear.

Headlight repair1.jpg

I made up a bracket from some aluminium scrap:

Headlight repair2.jpg

To help strengthen the repair I used some epoxy glue and then pop rivetted the plates into the headlight shell and temporarily bolted them up until the glue set.

Headlight repair 004.jpg

A bit messy but I hope you get the idea.

Headlight repair 006.jpg

Headlight repair 007.jpg

The pop rivets don't look too bad - especially as the headlight plastic is in such bad condition. Cracked and crazed by sunlight. I am not going to get that many more rides out of it cry

Headlight repair 009.jpg

Whilst doing the work, I spotted another substantial crack indicated by the blue arrow which I have also plated in the same way.

The pink arrow indicates an earlier repair where I had used some Araldite to put a strip behind the top of the unit to stop it cracking any further.

Headlight repair 012.jpg

I hope that maybe helps someone wink



Exeter, Devon, UK

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Posts: 16

Very nice.

Used some old meccano myself.

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