Ironhead headlamp housing cracked again

[eddie XLX]

Hello from Germany!

The housing of my headlamp (XLX 1985) is cracked again. This time it lasted only 4 years, then it cracked again around the reinforcing plate. Does anybody has a special trick to avoid these cracks (or to avoid the vibrations – rubber gadgets ore something)?

Greetings from a hot and sunny Southwest Germany
Eddie

[JB in NC]

When I worked on a lot of SuperGlides and Sportsters, I kept a repaired headlamp shell on the shelf, because the problem was so common. TIG welding or brazing is the proper repair. MIG welding will often cause stresses that will make a future failure inevitable.

Try to use a genuine Guide headlamp shell, the aftermarket ones are thin & flimsy.

Jim

[cazz1000]

I drilled 4 small holes, through the top of the housing and the plate that spot welded on the inside of the housing and pop riveted it. then use jb weld to reinforce the cracks. Works pretty good on my 83 xlx.

[doodah man]

When mine cracked, I replaced it then cut a 1” piece of rubber fuel hose and jammed it between the bottom of the headlight and the fork brace - like a little shock absorber.

[Captain Johnny]

I remember Doctor Dick advising what doodah man did and cazz1000's fix sounds right. I did both.

Piece of hard rubber. Here are the rivet heads.

[eddie XLX]

Thank you very much for your ideas! I will try it!