Cracked Headlight Potential Repair

[Br04dy]

Hi,

I was washing the car (MY17 XC90) last week (must admit it had been a while) and noticed a very feint crack. The car was MOT'd at Volvo in January so I can assume it was recent, as I appreciate a cracked headlight is an MOT failure.

Photos below:

https://imgur.com/a/8Mlm91N

https://imgur.com/6dbiCWp

https://imgur.com/oBqHfC2

I've called up a few places:

Official Volvo bodyshop who have advised replacing headlight. Stated due to potential for refracted light (blinding other drivers) they can't repair. They will check but likely replacement unit will involve going to Volvo garage to be accepted by car (I presume calibrating) and having bumper off for install. Price for new headlight is circa £1400 plus fitting .

General bodyshop repairers have also advised replacing headlight unit, potentially with secondhand unit off ebay. A quick scan of eBay shows second hand headlights around £300.

Windscreen repair company who advised could not repair.

I have also messaged a paintless dent removal company to get their opinion, no response yet.

I've searched a few places on the internet, I'm led to believe the headlight "glass" is polycarbonate and methyl methacrylate would be the likely "glue" with a good capillary effect to close the crack. From looking closely at the crack nothing is missing and no moisture is getting into the unit (yet).

Options to me are:

- Claim on my insurance, my excess is around £250.

- Keep searching for local repairer.

- Attempt repair myself (if I'm not happy go and claim off insurance)

I feel nervous about saying this on an Internet forum but any advice welcome!

[rxtian]

Looks like an stone has hit it to me.

I suppose the good news is that it doesn't appear to be in the way of any significant amount of light.

If it were me, I would seal/glue it ASAP and see if it seems to stay together and sealed. If it doesn't, you're not really in any worse position than you are now...

[Philip Fisher]

Different materials I know, but I repaired a stone bullet hole in the glass of the headlight of our old family 740. I used araldite. It passed every MOT and didn't leak for the remaining 12 years we owned the car.

I would attempt a repair. If it stays dry and passes an MOT you are sorted.

[AB-UK]

Saw a TV advert yesterday for Gorilla clear glue.
That might do the trick

[shagaboopon]

I'd say that looks unlikely to be a MOT failure if its not leaking. Personally speaking I'd leave it till the next MOT and if it fails run it through insurance as the car is a pricey model. If there is no immediate requirement to fix it you can also keep an eye on ebay for a cheap one to appear.

I had a tear on my front passenger door card of my S90 and happened upon someone selling a used item in good condition for £95 the other day which is half to a third of the price that others were listed at. Prices fluctuate and you may just stumble on a Good deal if you're patient.

[XC90Mk1]

That has not gone past the visible area by much and is mainly on the seal. In reality if you left it I doubt it would cause an issue however as noted you don’t want it to spread.

The smart money is on reviewing WIPAC and such like to determine what make of headlight material it is and then use bonded type adhesive.

Structurally the light appears sound however you simply don’t want it to break out.

I would suggest finding a good adhesive however as a minimum you could brush it with a toothbrush to remove any loose debris and then use araldite. I would apply it via a tooth pick so you can get into the root of the crack and allow the capillary action to take place.

Post glue use a scalpel or razor blade to remove any over application.