I had a Xenon bulb fail on my R56 Cooper S and when I went to replace it I found that the bulb holder was very loose (flopping about). I removed the light assembly and using a heat gun took the lens off of the front of the headlight. Inside I found that one of the three mounts for the Xenon assembly had cracked and split apart. I've epoxied a carbon fibre and fibreglass laminate to back the repair, and an epoxy fillet strengthened with milled fibre on the inside, but I'm not confident the repaired part is as strong as it was originally.

I can't find any part number for this, does anyone know how to find a replacement? Photo below is taken mid-repair.

 

Can't get it on its own. you will have to take the headlight apart and glue it back.

 

Hi - I have this same situation. Can you please confirm if the part in the photo is available to purchase? Thanks!!

 

Hello,

Edit, you cant get it on its own. Best bet is to replace the headlight aftermarkets you always wanted or get a used pair that are damaged and take that part out.

 

The repair I did is still holding up well. It is currently -11 degrees Celsius (12F) and the roads are rough, which is a pretty good torture test.

 

Good to hear! I tried similar repair that didn't last too long. Need to try again...fun!

 

It's a nasty part to epoxy, and hard to clamp in any meaningful way. I did the carbon/fiberglass backing first and then did the epoxy fillet afterwards.

 

I’ve done mine also, passenger side. Used J-B Weld and increased the area where the repair is to add strength (hopefully). I was able to reach into the access for the bulb and used hemostats to hold the part and get the screw started. It was tedious but I didn’t risk breaking the seal around the lens.

 

I repaired mine with JB weld 1 year ago, still working perfectly.