The title pretty much says it all, I noticed my passenger side headlight beam didn't seem quite right, like it was drooping or something. I poke around and try to adjust it, thinking that was all the matter. and then I saw this...



This might offer a better perspective:



It seems like the whole plastic shroud of the light needs to be replaced... any ideas are much appreciated.

 

Yup, the whole thing has to be replaced. :(

You may be able to epoxy it back together, but you'll want to find a way to reinforce the joint, like a doubler of some kind.

 

BTDT - the headlight's plastic housing is broken.
Mine went out at around 40K miles while still under warranty. I attributed the failure to cheap plastic + unforgiving run flats + NYC potholed streets. Boston roads qualify just as well.

I ended up having the headlights replaced and ditched RFTs in roughly the same time-frame.
You could try to epoxy the mounting leg back to the housing, but in my experience, glued objects tend to come apart sooner than you wish.

Maybe a good time to undertake Xenon upgrade?

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Xenon upgrade isn't in the near future for me, unfortunately my budget works around my needs more than my wants.

So epoxy, gorilla glue, since it is an unseen part maybe even duct tape? What do you guys think'll work best?

 

I'd try a 2 part epoxy. Used correctly that joint will become stronger than the rest of the plastic.

 

A good epoxy, but reinforce the joint with a doubler plate of some kind. Maybe get a piece of plastic and whittle at it until it matches the contour of the parts around the break? Or maybe a piece of metal, like plumber's strapping, that can be formed a bit around the plastic bits?

And then, of course, you'll need to find a way to hold everything tightly together until the epoxy sets up.

 

That's not a bad idea, kind of like putting a splint on it for reinforcement. I'll definitely have to try that when I get my mini back out of the shop.