Headlight covers (again)

[BobM]

When I built the car I bonded the headlight covers on, as per manual. First wet day out they 'misted up'. Trouble is it wasn't condensation, it was water which had ingressed from the back. I took the rear covers off, removed the lights and managed to clean up the inside of the polycarbonate cover and the black gelcoat. Of course it's all happened again, and since it's water off the road the inside of the lights looks pretty mucky. I've managed to get the covers off again, but am now wondering how best to refit them, and the best way of sealing the rear cover.

I really can't see any way of getting a completely watertight seal on the rear cover without bonding them on, which isn't an option. This being the case making the polycarbonate covers removable seems an increasingly attractive option.

I've read through the previous threads on this subject but wondered if anyone's had any thoughts on the subject more recently? Trouble is they look much better bonded on than with button head screws

[US-GTR]

I think they would look nice with some stainless counter-sunk screws. That would keep the flow of air the same and have the look of rivets. My 2 bits.

[GTRMikie]

I thought this would be a potential problem during my build so, using the outside of the rear cover as a template, I made a GRP "lip" about 1 inch wide which I then bonded to the inside of the bonnet round the light aperture. The rear cover then fits inside this "water deflector" For extra protection it is easy to seal between the lip and the cover with some waterproof tape over the join. I have never seen any misting or water penetration in my lights, and that included a track day in torrential rain last year.

[builder]

GTRMikie said:

...I made a GRP "lip" about 1 inch wide which I then bonded to the inside of the bonnet round the light aperture. The rear cover then fits inside this "water deflector"...

Mike, do you have any photos of your installation?

-- Scott
Reno, NV

[GTRMikie]

Scott

I will try and organise a photo, but it may take some time.

Mike

[k wright]

The lip sounds like a great idea. the best that I've seen on similar setups is the rear cover is bonded to the fender and never removed. The clear cover has a foam gasket and the lights are serviced by removing the cover. The midplate on the Ultima prevents this setup.

ken