What can repair/fill cracked plastic of headlight casing?

So my square headlight casing (black plastic) is cracked (not sure if all the way thru) near the corner which is also near screws.

Any suggestions for filler/repair product that can also be painted/stained??

I'd hate to take it apart eventually and just have the corner crumble apart at the crack.

 

Fellow forum member skills4lou showed me how he "plastic welded" a piece on his XJ750. Might want to PM him.

 

hmmm maybe.
The cracks are right around the lower screw "bumps"
I'm afraid if I disassemble it the parts will just fall off.

Something like this might work if it's black or paintable...
http://www.amazon.com/Permatex-84115-Pe ... B000ALBZK8

 

Did a little youtube search and found this. Pretty much the same way I do it, but I use an old Wen iron with a large flat tip attachment.
low tech plastic weld

My headlight bucket broke into about 4 little pieces down there, and I got it all back together.
An actual plastic welder works better, but this gets the job done.

 

I watched that video today LOL
HMMM where to find black plastic... zip ties?

 

Yup, I've used 'em. You get a better weld if you can match the materials: PVC, CPVC, PA, Acrylic etc. You can actually get the welding rods from HF, but I've always just used whatever is laying around. I used zip ties on my bucket and it looks decent and holds well.

 

Home Depot has all different sizes of black zip ties.

 

Drill a SMALL Hole at the end of the Crack to PREVENT the Crack from spreading. Until you terminate the crack; it will keep-on getting worse.

Put the Piece together and TAPE the CRACK together on the FRONT SIDE. (The Outside. Use a tongue depressor along the joint if it is unstable.)

Look at the back side.
Cut a Paper Template to go over the Crack and EXTENDING 1-1/2 Inches Beyond the Crack in all directions.
Trace the Template onto a piece of ALUMINUM Screen Door Repair Screen
Make (2) two Repair Pieces of Screen.

Mix a sufficient quanity of: "5-Minute Epoxy / Plastic Repair Type.
Spread Epoxy down on surface to be repaired.
A thin layer that will hold the screen in place,

As the Epoxy begin to cure --> Lay-on the Screen!
Push the Screen onto the Epoxy and "FORM" it.
(It may be necessary to Pre-cut the Screen for tough angles. If the Screen "Folds" ... let it fold and continue "SEATING" the Screen into the BASE Layer of the Epoxy.

I use a Regular Table Knife -- Butter Knife, a Putty Knife, and a Paring Knife as TOOLS to work the Epoxy and Screen)

Just as soon as you complete getting the Base and Screen on to the repair ... begin mixing the 2nd Coat.


Apply the 2nd Coat of Epoxy on over the Screen and add the 2nd Layer of Screen.
Once the 2nd Layer of Screen is in place ... Mix more Epoxy and FLOAT IT all over the 2nd Layer of Screen.

If you are using "Side-by-Side" Syringe Epoxy ... shoot some away from the Mix and scoop-up the Hardener and add the Hardener to the Final Mix.
It will let the Epoxy FLOAT easier ... PLUS ... Harden FASTER.

Once you get the Back-side of the Repair done ... do the front.
Rough-up the "LINE" of the Crack with 100 Sandpaper.
Mix Bondo or AutoBody Glasing Putty to conceal the Crack
Let the repair completely dry 24 Hours.
Sand smooth with 320
Begin wet sanding
400, 800, 1000
Prime
2nd Coat Primer
Wet Sand Primer
Paint
Dry
Ride!

 

I may take a picture of the cracks tomorrow.
The size/location of these exact cracks may dictate what I should do.

Though rick's long post is probably great info in general