DIY Broken fog light lens fix

[saturnine]

You probably all forgot about it, but one of my fog light lenses is cracked. Unfortunately you can't just buy the glass lens from Acura, you have to buy the whole fog light assembly which is ridiculous. So, I read that Lexan UV resistant plexiglass works as a fix. I decided to go this route since it seems like a replacement glass lens would just break again anyway. I finally got around to fixing it this weekend, so here's pics for you voyeurs Don't know if this will be useful to anyone else, but here goes anyway.

Removing the cover. Some believe you have to remove the bumper to access the fog lights. This is not true, but I found it out the hard way.


Once the cover is removed, there are 4 screws to remove


Unclip the wire to the foglight (shown already unclipped)


Preparation


This stuff's pretty cheap, so even if it doesn't last, it's no big deal. Note the thickness.


My new jigsaw, purchased for this project (I was initially going to use a Dremel rotary tool, but I am uber glad I got the jigsaw instead-cheaper too)


Use a screwdriver to unclip the lens cover; careful, it's plastic


Glass broken out & glue cleaned out


After cutting to size, I needed to sand & smooth the edges to fit properly. I did end up using a dremel sanding bit that I just put in my drill. Worked quite well, thank you. This is the part that took the longest.


Near perfect fit


Drying. Had to clamp it down since the front of the fog light is slightly curved.


Dried for around 24 hrs. Probably could've used a bit more silicone, but oh well.


Cover replaced.


Finished product


Other side w/the glass lens still intact

[djbme83]

nice write up gregg. how much was it total, minus cost of jigsaw?

[saturnine]

Originally Posted by djbme83

nice write up gregg. how much was it total, minus cost of jigsaw?

thx. I think around $12

[djbme83]

that's a steal right there. much better than buying the complete housing from acura

[saturnine]

Originally Posted by djbme83

that's a steal right there. much better than buying the complete housing from acura

I thought about just replacing the other one too, but I figured you can't really tell by looking at them, except the glass one has some pits in it so I'll just wait until it cracks. I cut out 3 extra lenses tho, they just need to be shaped.

& it was an excuse to buy a new tool

[djbme83]

Originally Posted by saturnine

I thought about just replacing the other one too, but I figured you can't really tell by looking at them, except the glass one has some pits in it so I'll just wait until it cracks. I cut out 3 extra lenses tho, they just need to be shaped.

& it was an excuse to buy a new tool

that's probably the most important part

[saturnine]

Originally Posted by djbme83

that's probably the most important part

you know you're old when you get excited about buying tools

[Slynky]

Originally Posted by saturnine

& it was an excuse to buy a new tool

Tim, the "Tool Man" Talyor would be proud of you, Greg!

Looks like you bought a vise, too (peeking in the background a bit). Got my first vise last year for Christmas along with my first rotary grinder. Grinders are one of those things you never really think about needing till, well, you find yourself doing sanding/grinding the hard way. Mounted both on my hardwood (maple) woodworking bench I built about 15 years ago.

Along the lines of tools, I got that socket set "free" even though I was really getting them for the CAI (whenever I can locate the fucker for sale!), my wife said it would come in handy other times. Anything I do to "Silver" comes out of my "allowance", so it helps that the tools came free.

Finally, GREAT write-up, Greg! It should make the sticky list as there seems to be too many problems with foggies and cracks.

[Slynky]

Originally Posted by saturnine

you know you're old when you get excited about buying tools

I love Lowes and HD. Wifey juices her gams walking into Office Depot. We both have our weaknesses.

[QKSLVER03]

Nice write up Gregg, and great job working on that lens.
I wonder how much Acura charges for the replacement housing??

[QKSLVER03]

Speaking of toots... I can relate about a week ago when I was installing my torque damper, I really needed some tools cause the little cheap ass tool set the wife had bought me just to get me by was just not cutting it anymore. Fucking peace of shit tool set. Anyway, I went down to sears and there was a 263-piece set ($470.00 value, craftsman of course) for $199.99 so I picked that shit up, and my father-in-law bought me 2 of those open end adjustable wrench things because those don't come with most of the tool sets, and I needed those to adjust the setting on the torque damper to be a little stiffer... Anyway I think I'm set for regular and deep sockets now.

[saturnine]

Originally Posted by Slynky

Looks like you bought a vise, too (peeking in the background a bit). Got my first vise last year for Christmas along with my first rotary grinder. Grinders are one of those things you never really think about needing till, well, you find yourself doing sanding/grinding the hard way. Mounted both on my hardwood (maple) woodworking bench I built about 15 years ago.

yep, got the vice for the project too, but I shoulda gotten it a long time ago. I thought it was a great buy for $20.

Originally Posted by Slynky

Finally, GREAT write-up, Greg! It should make the sticky list as there seems to be too many problems with foggies and cracks.

Thanks!

Originally Posted by QKSLVER03

Nice write up Gregg, and great job working on that lens.
I wonder how much Acura charges for the replacement housing??

well, I think you can only buy the replacement fog light setup as a whole, so about $300.

[QKSLVER03]

Originally Posted by saturnine

well, I think you can only buy the replacement fog light setup as a whole, so about $300.

Nuh man... I could have sworn I've seen somewhere where they only sell one housing only if you need it... hang on... *checking*

[QKSLVER03]

Ok I got it!!! right here, but you did such a good job fixing it... it won't matter.

right replacement fog light replacement lens for 02-06 RSX:

http://cgi.ebay.com/ebaymotors/Acura...m Z7996133107

left replacement fog light replacement lens for 02-06 RSX:

http://cgi.ebay.com/ebaymotors/Acura...m Z7996133112

[djbme83]

good find driss. i, as well as probably everyone here, would have gone the route gregg did