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Discussion Starter #61
It’s been a headlight “restoration” morning indoors.
lots of wet sanding, cutting compound with a sponge drill bit and ending with a high gloss wax to protect. I sanded with 400, 600, 2000 and 3000 grit but wasn’t happy first time around so I sanded fully again and added a 1200 grit after the 600.
After the 3000 I did 2-3 passes with a cutting compound and then a good clean and wax.

a lot of the marks are inside the lens (I’ve had a hairdryer blowing into them to get rid of condensation marks). They’re not perfect but they’re a lot better than they were. And I can’t complain for £25. Anyway, here’s a bunch of pics.

to start with
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First full sanding
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Cutting
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I’ll skip to the end result after the 2nd round of sanding and cutting and waxing.

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I had some Philips X-tremeUltinon gen2 H7 LED Bulb (Twin) | PowerBulbs UK
fitted last year which are excellent but at around £120 not cheap and can "apparently" last up to twelve years, i had these before which are good but only last a few hundred hours

Out of interest i just looked at the prices of GSI etc headlights, i paid £44 for a brand new Hella headlight around seven years ago but now they are over £100 each!
 

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I went with leds in the H Sri, made a big difference, iv changed onto bixenons now with led main beams


Sent from my iPhone using Tapatalk
 

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Discussion Starter #66
Yeah even the knock off headlights were £50-£60. These weren’t in terrible condition, just needed a little tlc.
As far as bulbs go I’m not gona go crazy and spend loads. I’ll just find some that aren’t too yellow and look decent
 

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Mine are still in fairly good condition but may need polishing at some point,
£20 odd should get you a fairly decent set of halogens.
 

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Discussion Starter #68
Got out in between blizzards this morning for the final bit of Fiesta MOT prep.
rear view mirror is stuck on (epoxy). New boot struts so the Mrs isn’t killed! And new flexi fitted with no leaks 👌🏻

Here’s the old ones issues
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Only thing I couldn’t do was the o/s cv boot, the driveshaft just would not come out, and as I’m on a drive with a garage and it’s constantly freezing, raining and/or snowing I’m gona let the garage sort it pre-MOT.

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Discussion Starter #69
Got a little bit done today before I ran out of light and was a solid ice block 🥶

All I wanted to do was get the rear bumper off and remove the tow bar.... job done 🤘🏻

First tracked the electrics back to the n/s light switch area.

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I’m not the greatest when it comes to electrics so any advice on the best method to deal with the tow bar wiring would be appreciated.

Then got the bumper off. The two top wheel arch torx screws both rounded of course and had to be heavily persuaded to let go. I did order new torx screws tho for this exact issue.

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Then the tow bar bolts x 5, which I had pre soaked a couple of times in wd40. Came off fairly easily in the end

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Annoyingly the n/s bumper mount is broken and it’s riveted to the car 😫

Ideas for sorting this also welcome

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O/S is fine tho. I’ll be getting the new back box on ASAP and you can all have a good laugh at the condition of the existing one 😆
 

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Discussion Starter #70
Ok so I got the old back box off and immediately ran into a problem....

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The hangers on the new one are further back than the old one. I guess that’s because it was on a coupe before 🤷🏼‍♂️. So both boxes are currently at the welding place around the corner so he can use the old as a reference to either move the new ones hangers or, transfer the old hangers onto the new box.

As you can see, the old was in a bad way

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And side by side

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Also got 2 new tyres and got the new wheels on. Sorry for the poor pics

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Discussion Starter #71
Only got a little done today between schooling the mancub and torrential downpours.
1) Removed the tow bar wiring harness.
2) Traced a boot leak back to the tailgate rubber harness protector.
3) Picked up the back box from the welder.

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Removed, cleaned and refitted but I think it’ll need some sealant to keep it dry. Also blew the central locking fuse when I removed it (only 20A fuse, fixed) so not ideal. I will sort it ASAP.

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Fiesta is in for it’s MOT tomorrow so fingers crossed it passes 🤞🏻🤞🏻🤞🏻🤞🏻🤞🏻🤞🏻🤞🏻🤞🏻
 

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Discussion Starter #72
Finally got the back box fitted

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Can’t say there’s a noticeable sound difference (still a tractor 😆). But it’s a vast improvement. Took a little fettling of the hangers with the dead blow hammer but it’s a pretty good fit.
Also replaced the leaky antenna gasket (again!) with a brand new full unit.


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I went to buy a 2nd hand bumper today but it turned out worse than mine. So repair it is
 

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Annoyingly the n/s bumper mount is broken and it’s riveted to the car

Ideas for sorting this also welcome
I've never tried it myself, but I've seen quite a few people repair plastic (and even re-create missing sections) using baking soda (not bicarbonate of soda) mixed with super glue. It could be worth looking at online.
 

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Discussion Starter #74
I've never tried it myself, but I've seen quite a few people repair plastic (and even re-create missing sections) using baking soda (not bicarbonate of soda) mixed with super glue. It could be worth looking at online.
Sounds interesting, I’ll look into it cheers mate.
I’ve got some Tiger Seal too. Also ordered the paint, got epoxy, primer, laquer and filler. I’ll get to the repair ASAP
 

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Discussion Starter #75
And so it begins! Bumper repair stage 1.
Removal. Clean to see what needs doing exactly. Initial sanding of areas that need attention/repair. And crack repair part 1.

So first off here’s the pics after a clean so you can see what needs fixing.

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As you can see, no small amount. A smart person would probably just get another bumper and have it painted. But this is a learning opportunity to see what can be done here 👌🏻
If it doesn’t work it doesn’t work 🤷🏼‍♂️
 

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Discussion Starter #76
I started with some initial rough sanding at 120 grit to get some high spots and gouges down and to highlight what I need to fix.

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Then I took it inside and wiped it down to start the crack repair.
I heated the area up with a heat gun and pressed it as much into position as I could, the taped the top in place with masking tape to hold it.
I then used a soldering iron and some staples (flattened out) to do some “stitching” to give it a bit of strength and stability for the next step. Epoxy


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I used a 2 part epoxy and a normal bandage to secure the crack.

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Discussion Starter #77
So while all that sets overnight I attached the broken bumper mount initially with some Tiger Seal and tape. I’ll go around again to make it extra secure once the first round is dry.


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Oh and the fiesta passed it’s MOT! 🤘🏻🙌🏻
 

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Congratulations on the fiesta and the repair is come along very nice and good use of every day items in the garage should be a great mk4 when it’s all done well done my man


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Discussion Starter #79
Congratulations on the fiesta and the repair is come along very nice and good use of every day items in the garage should be a great mk4 when it’s all done well done my man


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Cheers, I’m happy with the progress. It’s a good experiment whilst the cars not needed for work right now. Filler and paint prep today I reckon 👍🏻
 

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Discussion Starter #80
Right, this is gonna be pic heavy and over a couple of posts.
More bumper progress.

The epoxy has held well and it feels strong but it wasn’t very flat so, after an initial clean, I went at the cracks, high spots and bulges with the heat gun and a flat cork sanding block (to push the bumper into shape). Then sprayed it with a cold water hose to solidify the new shape.
That took a few attempts and really improved the shape.

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Attempted fixes on the broken mounts too
(Time will tell, but I’ll do more tomorrow)
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