R50/R53 :: Hatch Talk (2002-2006) Cooper (R50) and Cooper S (R53) hatchback discussion.

Re-sealing Factory Tail Light Housings

Old 03-07-2019, 11:07 AM
WheelNut is offline
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Re-sealing Factory Tail Light Housings

On my R53 the tail light lenses are separating from the housing on one side. Water is entering through this gap. I read a comment on a Youtube video stating that the tail light lenses and housings are ultrasonically welded at the factory. Anyone here know the best way to re-seal the lens to the housing?

I haven't tried separating the lens yet, but I would assume it needs to be pried off, which would risk cracking the lens. If I could get the whole lens off I could bond it back onto the housing with a silicone or similar adhesive (something like what Honda uses on their headlights). If I can't remove the whole lens I'll have to bond the 15cm section that has separated. I'm assuming the lens is polycarbonate and the housing is ABS. A quick search online shows that a solvent based methylene chloride adhesive would work best to bond these parts together. Maybe even Testors model glue might be easy to handle and cheap (toulene based). Thoughts?
Old 03-08-2019, 11:35 AM
Mini invictus
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My thoughts are, I am very interested in this. I replaced the tails on my Mini because the right was hazing internally, or humidity. Now the same right side tail is hazing. I have thought about opening them up polishing them and sealing them. I have not gotten around to this, so thank you for informing me on them being sonically welded.

My initial idea to open them up was to bake them in the oven, a trick from another car. I wouldn't mind working with you on this. and Hey if you need I have a an extra set of tails sitting around.
Old 03-08-2019, 05:35 PM
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Some people open them up to clean the inside only to find out that its the lens itself that oxidizes. Some of it is a film on the inside Some you can clean up and some its so milky in the lens you just replace them, that's what i did and went to the euro ones, Euro taillights https://www.northamericanmotoring.co...ts-06-mcs.html The early 20005 MY seam to have it the worse, I am on my new ones and they are still pretty clear after a couple years.

DIY on tail lights separation: https://www.northamericanmotoring.co...il-lights.html

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Old 04-10-2019, 10:46 AM
Mini invictus
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Thanks for the link. I am hoping they could be salvaged, the haze is minimal.
Old 04-10-2019, 11:13 AM
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If you decide to separate and then reseal your lens, I recommend my go to adhesive "E6000" more about it here...

E6000® Glue, CLEAR, Medium Viscosity

E6000® Glue was manufactured and sold as a high-performance industrial adhesive for over 25 years, E-6000® became a hit in the craft market with its superior performance, flexibility and versatility.

E6000® Dries Clear & Paintable, Washer/Dryer Safe, Photograph Safe, & Waterproof.

E6000® Self-Leveling Formula
An indispensable maintenance tool, E6000® allows the kind of permanent repair and maintenance of equipment that may have been too expensive or difficult in the past. E6000® provides adhesion strength and versatility not found in silicones and rubber cements. Its strength in adhering metals, glass, rubber and plastics makes it a universal vehicle maintenance and repair solution. Also, because it's self-leveling, E6000® may be used as potting material in electrical and computer applications.

Best of luck.

Motor On!
Old 04-10-2019, 11:19 AM
Mini invictus
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Thanks for the recommendation. I love that stuff, it works on everything. Half the clothes you own have it somewhere haha.
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