Headlight gear fix problem

[Warren Seale]

I installed the brass gear in my headlight motor assembly about 6 months ago and I'm having a heck of a time keeping the thing together. I've tried 3 different epoxies 2 x each for a total of 6 times and after working for a little while it lets loose. It always fails in the up position when the headlight door linkage is under a heavy load. Besides the epo-tek epoxy that comes with it, I used industrial epoxies designed to adhere with plastic. I also cleaned the surfaces with methanol and acetone prior to applying the epoxy. I gave up and went out and bought a new assembly. I ususally don't go down in defeat like this but I'm at wits end with the stupid thing.

What have you all down that makes this work?

Thanks,

Warren

[Ryan96WS6]

How long did you let it sit. Mine sat overnight just beacause I ran out of time when I was putting it back together. I also left it in a clamp the entire time. Only one of my motors has the brass gear the other one I was able to do the free fix. That side I didn't use apoxy on so there is a gap but it still works fine. I will replace it with a brass gear eventually.
Ryan

[BAS]

I tested mine after I put it back together I think.

Just make sure you mix them and use enough to coat it. Think of it more like the caulking on your bathtub.

Originally posted by Ryan96WS6
How long did you let it sit. Mine sat overnight just beacause I ran out of time when I was putting it back together. I also left it in a clamp the entire time. Only one of my motors has the brass gear the other one I was able to do the free fix. That side I didn't use apoxy on so there is a gap but it still works fine. I will replace it with a brass gear eventually.
Ryan

[wolfdogs]

i gave up and got a friend of mine to buy a motor at cost from gm for the hawk. its still in the box for the "new owner" to buy the car and put it in......hahahaaahah

[furyus65]

Mine would not stay together either so I just ziptied it together until I get a chance to do it correctly. noone would know unless I showed them so I am not in a big hurry.

Jason

[Joe 1320]

Ever try JB Weld? That stuff holds like iron.

[Black97]

Haven't had to do the fix yet.

We use epoxy at work to fix the windings of the generators. Usually that stuff has a shelf live. If it gets too old it takes longer to harden and sometimes doesn't harden enough, just stays rubbery.

Epoxy should also be stored in a cool area where it will last longer.

Cleaning the dirt and grease off with Acetone is good. If the housing has a really smooth surface on the outside, roughing it up with some sandpaper will help bonding.

Mixing is important too. You might get too much or not enough hardener and it gets like glass and cracks real easy or stays fairly soft.

Temperature has an impact on curing too. The colder it is the longer it takes if it even cures. We usually try to speed up the curing by adding some "heat".

Not sure about JB Weld. Is it like Devcon (Metal Epoxy Compund)? This stuff we use more to fill in gaps or holes or build up surfaces and then you can machine them. Could probably work too if you apply a nice coat all the way around.