Hello,

I'm new here and I have the same problem like many others-there are no parts available for the replacement of the plastic covers of the headlights neither we can buy the whole headlight assembly new.

I make a research on alibaba and some other chinese web sites, they are offering these plastic covers for newer cars and they are cheap.

Maybe someone knows a company or manufactor which can produce them. I'm pretty sure that thousands of us would like to buy brand new ones.

here is one link

https://www.alibaba.com/product-deta...6554kijaE2&s=p

 

I just wrote with this manufacture. They need 3D drawings in STP or IGS format of the covers and then they are going to send an offer. Can someone support?

 

I would like a new set also

 

There must be some new ones around, $800 to $1,000 each.

 

If we found someone with a 3D scanner who is sharing the data with us these will be cheap- I think not more than 50 bugs for one.
But without support - no way

 

I noticed that you’re new to the site, welcome.

Is this issue as a result of something recent with your XF?

accident, rock.....

180 is correct these are not inexpensive but used and new replacements Still exist.

interested in hearing the back story, what’s led you to the forum and the headlight request.

We are all interested in a cost effective solution, what do you have in mind.

 

Hello, I have currently no issue with these covers-J just poilished mine. But who knows what will happen in the future?
My approach is:
1. Get 3D drawings - the data in STP or IGS format
2. I already found a manufacture in Taiwan, Shenzhen Kaier Wo Prototyping Technology Company. which can produce them
3. I'm not a salesman therefor I hope to find someone who can order them or I'm going to find one of these asian dealers for aftermarket parts who can do this
4. All of us would be happy - we are able to buy new cheap parts.

 

The mould would not be cheap and the cost of it has to amortized over the number of parts produced.
There is a left and right hand part.so two moulds are required.
Removal of the lens from the main body is not a clean and easy operation.
The chances of getting someone to make these moulds based on the probable number required are slim.
Look after the headlamps you have.

 

Some of the supplier responses for this application are more than likely considering reproducing the lens using 3D printing methods which would be the least expensive approach. This process requires using 3D data files such as IGS, TIF, and others that define the object's geometry. However, the Crossfire lenses are made of polycarbonate (Lexan) material which may not be readily available in a raw material form suitable for 3D printing. For those not familiar with 3D printing systems these units are used in making prototype components using various types of polymer or plastic materials. My guess would be that the overall light transmission through a lens made with this method would be ranging from fair to poor. Obtaining a data file defining the Crossfire lens could also be a problem. This can be obtained by adding another step which would involve scanning the surface for data points, more$$$$.

 

3D printing would not work, the plastic has to be homogenous to get the clarity.
I think the best way to replace the lens is to cut off the front two dimension curved portion of plastic and replace it with a one dimension curved piece bonded to the old lens base. I think 1/8” thick PC sheet would be fine. The cut would follow the vertically aligned radius on the headlight and be done on a computer controlled machine.
The new plastic lens would be bent on a polished curved form in a heated oven, bending mainly under its own weight.
Addition force could be applied if required to the edges and any marks removed when adding a radii to the edges. The
radii could be added prior to bending if no extra force was required.

 

me too please