I knew this would be an issue when I first found my truck, but I'm finally getting to it. Snapped off the three bolts holding on the housing, and took it inside to get a good look.
Well, it was better then I feared, but still not great.
the outer shell is still in good shape, but the brace/mounts inside are heavily pocked and weak. Those are mostly flat so those are easy enough to make new. The big problem is the panel behind the headlight bucket, the one that the adjuster screws and springs are attached to.
How should I go about trying to fix this part? I have some metal the same thickness to work with, but I'm not sure if rivets would work, or should it be welded? Should it be butt welded or lap welded? Cut out the bad material, or cover over it?
This truck is my first real body work project, so repairing rust is fairly new to me.
Anyways, the album:
46 Headlight Housing
