VW POLO 16v 6N-Mk3 Fog-Light Reconstruction:
I discovers that the right front Fog-Light of my car is complitly ruin (PN: 962 836-00R).
The cause is a hole in the enclosures top. During the winter - water filled the internal structure.
It was probably in this condition for ~3years... So it is full of corrosion now.
How / Why it was broken is unknown.
I could not find a new part on eBay or my local supplier. So I decided to go ahead and fix it myself.
It took me 3 fun week-ends.
Since I already had all the needed equipment, the repair costs were minimal:
- 4 Lemons.
- 10gr ABS
- 3gr Paint
- 5gr Epoxy
- 70x20mm Fiberglass
The condition as I discovered it:
The broken part of the enclosure
The front-glass is complitly covered with corrosion from the metal reflector.
The reflector...
Applying some natural Lemone juice
I squised ~4 Lemons into the enclosure in order to remove the corrosion from the front glass.
It also helped freeing the metal reflector from the plastic enclosure.
The front glass after applying the natural & fresh Lemon juice.
Waited ~20min and used a soft cloth to remove the corrosion.
Top: The left reflectors hinge connection
Bottom: The Right reflectors hinge connection
What it left from the reflector after cleaning it from all the corrosion.
I used Fiberglass and Epoxy glue to reconstruct the holes and frame.
Reconstruction of the missing parts:
I designed and 3D-Printed two types of parts for the reconstruction:
1. The H3 Halogen bolb housing.
2. Right / Left hinge connectors
I saved the original H3 locking mechanizm and glued it to the new H3 housing
The H3 light-bolb fits perfectly
Some painting job:
Painting the reflector:
For the 1st paint layer I used HUMBROL Enamel #22 (White)
For the 2nd paint layer I used HUMBROL Enamel #11 (Silver Metalic)
I had to enlarge the broken openning in order to insert the reflector.
I preferd not to open the front window and risk breaking it or not be able to properly closing it back.
Almost mission accomplished!
Testings and Assembly:
1. Test that it lights-up - Done!
2. Close the enclosures top opening - Done with a sheet of plastic and some silicon
3. Perform a simple water tightness test - Done in a bucket full of water for 24hr
4. Assemble it back on the car - Done
