Must have been a large stone, because there is a small hole, and scalloping around it. Not noticeable until you look closely, but seeing as I just put these on on Saturday, i'd like to fill the hole with something before water gets in. Does anyone know what would be good to repair this with?

 

A new lens (available here: http://www.rallylights.com/hella/500.asp ) would be my suggestion, followed by a set of these:
http://us.st11.yimg.com/us.st.yimg.c...n_1931_6856438
available here:
http://www.rallylights.com/hella/500.asp
or here:
http://www.4by4connection.com/hel500drivli.html

That way you comply with laws requiring auxiliary lights to be covered, you can still use the lights and you don't need to worry about stones.

 

Aeromax,

I recommend replacing the lens as soon as practical. In the meantime (while I was waiting for a new lens), I have put clear packing tape over the hole (prevents moisture entering and reflector damage). However, I do not recommend using the light with that tape on it.

If you do not want the hassle of putting on and removing light covers or stone shields, you could consider putting on some of that 3M headlight protection file (20 mil.). I put it on my Tardis. They say a 1 ounce stone travelling at 120 MPH will not damage the lens.

There are local and on-line dealers you can check with for a small sheet of that file. I got my kit from www.AutoPaintGuard.com (almost completely pre-cut and reasonable easy for a do-it-yourselfer to put on). Advice: Pre-cut a little undersize so it does not start peeling off.

 

There is no need for any of the film. Hella sells the clear covers that stay on forever and are meant for each lamp just as Spunky suggested above. I had them on FF200s and never took them off. They were perfect as designed for the lamp.

 

I had that same type of hole in a Bosch foglamp once. I turned into McGuyver, grabbed my Leatherman, cut a 1/2" circle of clear PET cut from a blister pack I took out of the the recycling bin... took a dab of RTV clear silicone onto the lens and glued that small clear piece in place.

The whole repair took maybe 5 minutes. It lasted a few years until I sold the car. That was in the days before LaminX type films though.

Replacement lens is the way to go. Make sure your lamps are in a reasonably heated place when you do the repair, and that all moisture is GONE from the inside. A hair dryer can help with that.