When replacing the fork, I discovered that the headlight housing was broken at the top. Most of the force that holds the headlight in rests on this small lip, so I needed to make a solid repair. After cleaning and roughening the surfaces, I used Loctite 2-part plastic epoxy to reattach the broken piece. In order to avoid the same thing happening again, I made a small metal bracket to support the headlight which attaches further into the housing. I spot painted the repair and while it’s not perfect, it isn’t really visible from a few feet away.
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