G28 - Simple Mans, Simple REDO of an G28 LP640

[Simple Man]

For the headlight made a flange/lip for the upper tub.  Clamped  in place inside the glass. Now there is a decent surface for the sealant and I like the way it sits in the glass

[Simple Man]

got the last dregs of engine items needed and installed engine hopefully for the last time

Now I can sort out the rear brakes

[Simple Man]

Added about 6 oz of csm to the top side,  then removed the original material from the bottom side, if that makes sense. 

Pretty happy the way it turned out.  Some dyna glass and rage gold to finish. 

Really leaning towards adding the fiberglass flange all the way around the lens. 

Good news on the drivers side very little warp and fits nice in the lens.   

[Simple Man]

Well the headlight build for the drivers side will go smoother from all that I have learned from the passenger side 

Decided to mount the upper tub recessed into the glass on the ledge.  The ledge at the top and bottom of the glass is wider and some adhesive will be used to affix it to the glass.  Going to try to locate another set of tubs for future use 

A recuring theme with the REDO... there always seems to be issues .

The fiberglass headlights are warped    After sanding the tub to fit inside the ridge and resting of the ledge the tub flares up.  Going to have to add fiberglass CSM to the inside to build it up.

onward!!

[Simple Man]

How to attach the replica tubs to the glass 

Thinking about this way. Trim the tub to rest on the inner ledge of the glass lens. Put a bead of sealant as pictured.

If the lens fogs up over time, the sealant will be easier to remove than if the bucket had the OEM flange.

something to ponder for a few days 

[Simple Man]

Well made some attachment brackets, or at least the first version 

[Simple Man]

I would hold off on the desiccant unless really needed.  It seems like it occurs mostly on daily drivers with seam problems which are driven in the rain.  The youtube fix? is to blow low pressure air into the headlight for a few minutes through the bulb hole thus removing the humid air that has accumulated inside the headlamp.  The warmer the air blown in, the less time needed.
01

(my thinking on this problem is that hot air expands inside the headlight when lights are on.  This breaks the seal of the unit.  As the air cools, it pulls in the moisture where ever it can like rain or washing the car.  Possible cure might be to drill a 1/4 inch hole at a location that is not visible (in the bottom?) and glue a cigarette filter in the hole.  This would allow for the air expansion/contraction without pulling moisture into the light bucket)  my $.02

Something to think about for sure.  Im not sure the heat blows the seams in the OEM headlights as the OEM headlights have drains in them. 

there is a youtube video that states having the lights on causes the problem in the OEM lights. 

I think the main thing I am thinking about when putting these together is how to get them apart if the lens get cloudy. With my removable bottom tub I can inspect the desiccant packets and replace if needed.  They turn color as they fill up.

I'm not sure what the solution is and even Audi hasn't figured it out

I'm a ways from sealing mine up so I will have to ponder.....

Thanks for the comments 01!

[01Lambiero]

I would hold off on the desiccant unless really needed.  It seems like it occurs mostly on daily drivers with seam problems which are driven in the rain.  The youtube fix? is to blow low pressure air into the headlight for a few minutes through the bulb hole thus removing the humid air that has accumulated inside the headlamp.  The warmer the air blown in, the less time needed.
01

(my thinking on this problem is that hot air expands inside the headlight when lights are on.  This breaks the seal of the unit.  As the air cools, it pulls in the moisture where ever it can like rain or washing the car.  Possible cure might be to drill a 1/4 inch hole at a location that is not visible (in the bottom?) and glue a cigarette filter in the hole.  This would allow for the air expansion/contraction without pulling moisture into the light bucket)  my $.02

[Simple Man]

Using some rubber washers with wing nuts.  Pretty happy with the seal.

I was putting a desiccant pack in my gun safe and was thinking of putting a couple inside the headlight once it is sealed to absorb any moisture.

[Simple Man]

For mounting the bottom tub, The location of one of the studs was moved.  The stud that was attached to the aluminum bracket, for the 3" lamp was removed.

Should be better in the new location.

[Simple Man]

Very Nice. Love the matte finish.

Thanks LB!  I believe Murci Me gave me the info on the paint that he used on his headlights.  I used a clear over the color.

[lambobuilder]

Very Nice. Love the matte finish.

[Simple Man]

Wiring is a tedious activity

Makes my eyes blurry 

[Simple Man]

before hooking up the wiring a mock up was done. Pretty happy how it is coming out so far

The edges of the top bucket need to be cut down to fit inside the glass.

Also no sure if the top surface (where the glass rests) needs to be thickened.

I want to be able to put a straight cutting blade in from the side to cut the adhesive easily that will be between the glass and the bucket.

[Simple Man]

Assembled the lamps in the bucket and did a mock up with the lower bucket. A nice seal with the weather striping