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Mk2 Bready headlamp adjuster repair

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I am restoring some Mk2 H4 round headlights and realised that they had the same old problem of the screw rusting and the thread in the plastic being damaged. I have failed a MOT because of this in the past. So I came up with an idea to fix it for good. This method of repair can only able to be done if none of the plastic parts are broken. Make sure the plastic parts are as oil and dirt free as possible. To repair it I cleaned up the adjusting screw with a 5mm die (nut) for the thread and a piece of wet and dry sandpaper to remove all the rust especially from the ball end of the screw. Next drill out the damaged plastic thread with a 6.8 mm drill. (this size is important for the next step) Using a flat head stainless steel 5mm rivnut insert it with the head of the rivnut towards the top of the the part with a little bit of superglue or epoxy resin around the rivnut to help hold it in. Before the glue goes off immediately apply some pressure with the rivnut tool to the rivnut to expand it slightly to further help it to hold it in. Too much pressure will split the plastic. Apply rubber or silicon grease (won't rot the plastic) to all of the screw to prevent it from rusting and lubricate it in the new nut. Of course there are other methods of thread repair (some that don't need special tools) but this way looks like it was meant to be there and it will never rust or corrode.  Of course I know that everyone does not have access to a rivnut tool so if anyone needs this done, PM me and I will do the repair for you.

Regards

Phil

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