Back to the headlight mounting again. This job just sits in between others when I get a bit stuck!

The first task was to get a better fixing point on the car mirror motorized mount. It had 4 little plastic loops that looked very easy to break off. I tried removing the mount outer cover to fix some hardpoints but it looked like I’d break it for sure.

The solution was to build up all around those little lugs and I found a few curry containers that I had saved that were the right size. Then followed a couple of days cutting out the bottoms and making rings as washers and a couple of them with a bit of the sides intact. I ended up with the plastic encapsulating those lugs completely and a very strong outer fitting with a bit of give in it.

I used 5mt to set it all in place and had a really good lightweight result.

Curry containers re-purposed

Reinforcement rings

A new, strong mounting area