Headlight extension MOD

by Joe73 Wed Sep 28, 2016 11:33 am

Just thought I'd share. I had 3 out of the 6 self tapping nuts, that hold the headlight extension to the fender, "strip" or kind of. They just werent holding well. So I decided to do something about it.

I took (2) 4" long, 1/4"x20, grade 5 bolts which only had threads at the bottom 1 1/2" or so. I pulled out the tap and die set and made them FULLY threaded. Then I cut them into 1" sections.

Then I used a hacksaw to cut off each stud (only where the self tapping nut bites in) on the back of both headlight extensions. Then I took a 13/64" drill bit and drilled a hole where the stud was located and went in about 3/4" inch. Plenty of meat on the part below where the stud was. With the stud cut off it kind of looks like a tower. After drilling the hole to about 3/4" I proceeded to tap the hole with 1/4"-20 threads. Use some oil for lubrication during tapping.

After all 6 holes were tapped, I cleaned out the holes with some brake cleaner and blew them dry with the compressor. Mixed up some JB Weld epoxy and put some in each hole. Then I threaded in the studs I made. Let dry overnight.

Installed the extension the next morning with a small washer and a nut that has a star washer built into it. I also thought of using a nylon stop nut but found that wasnt needed.

Just a tip I thought I'd throw out there in case someone runs into the same problem.

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