6R Headlight mounting

[SimonPoole]

Might have been better off trying to find a genuine 2nd hand wing in the right colour?

[amer6R]

Are you sure they painted it in candy white?
If you cant replace it give the fender and surrounding area quick buff it will help hide in fresh painted panel.

[POLOZ]

Might have been better off trying to find a genuine 2nd hand wing in the right colour?

Not so easy mate, been looking on Ebay like a hawk trying to find one and also been calling breakers however nothing to avail.

[POLOZ]

Are you sure they painted it in candy white?
If you cant replace it give the fender and surrounding area quick buff it will help hide in fresh painted panel.

Exact question I asked the fella on Ebay. The listing said LB9A Candy White.

I am going to invest in a DA mate.

[POLOZ]

Well guys more surprises

Sorted out the panel gaps finally and was installing the screws at the bottom of bumper to be greeted with broken plastic which I never noticed before.

Anyways removed the bumper again to find that the whole rad slam panel is broken from underneath

Is it a common thing on the 6R's? Also without removing the whole radiator, can the slam panel be replaced?

Going to price the parts tomorrow at VW's Don't want to buy the cheapy replicas on ebay.

[amer6R]

You dont need it hahaha. Btw. Keep the holes where the bumper clips in. I cut mine almost half the way up. Just make sure the radiator support brackets are ok.
Yeah all out job. But when you remove the support beam 4x 13 mm bolts, and 4 tx30 for rad support when you put it back add firstly the bottom 13 mm bolts and then 2x tx30 rad support then pull the cross beam up. Then add 2x tx 30 and top 2x13 mm cross beam bolts. Make sure that you pull the cross beam up, ot just mark it position before removing.
( These tx30 can spin so get a wrench and hold the nut insert from the back).

It is crucial for gap aligment! Close the hood before you put the bumper back!

[POLOZ]

Yeah all out job. But when you remove the support beam 4x 13 mm bolts, and 4 tx30 for rad support when you put it back add firstly the bottom 13 mm bolts and then 2x tx30 rad support then pull the cross beam up. Then add 2x tx 30 and top 2x13 mm cross beam bolts. Make sure that you pull the cross beam up, ot just mark it position before removing.
( These tx30 can spin so get a wrench and hold the nut insert from the back).

It is crucial for gap aligment! Close the hood before you put the bumper back!

Thanks for the suggestion mate. You made it sound easy enough. So basically I want to avoid disconnecting the radiator. I am sure I can replace the rad frame without the disconnecting?

You dont need it hahaha. Btw. Keep the holes where the bumper clips in. I cut mine almost half the way up. Just make sure the radiator support brackets are ok.

Are you saying yours was also broken? Did you just leave the bottom bracket in place? Seems like a common issue in 6R's?

[amer6R]

You cant without removing the radiator. ( At least i dont know how) I think it not possible.

I have trimmed my "radiator support" almost half way up to be able to squeeze a big intercooler. I have no issues.

I know that where your part is broken that it screws in the front lip of the bumper ( aka spoiler).

I have even cut the inside bracket on the bumper. If you dont want to change the broken part cut it off, or patch it up. Just make sure if you are running the plastic belly pan to secure it so it doest fall off.

I will insert a photo when I was mocking up the IC position, so you can see how far up I have trimmed the plastic radiator support and no issues at all.

IMG-810a975b401c0679addcb0d692984493-V~2.jpg (1.15 MiB) Viewed 1886 times

IMG_20210707_191609~2.jpg (1.71 MiB) Viewed 1885 times

I personally think if you cut or fix that part you wont have any issues. But if you want a perfect car change the whole thing.

[iichel]

I did a change to a darkside intercooler, and didn't need to chop a lot to be fair.
https://imgur.com/a/yeYdAwo

Anyways, that's a bit off topic

[amer6R]

Yeah, i made a mistake buying then measuring . But my core is 210 mm tall and 80 mm thick. Its from a 2008 Sprinter. If I was to do this a second time i would buy a thinner core ~ 60 mm and height ~ 170 mm would be perfect.

[POLOZ]

You cant without removing the radiator. ( At least i dont know how) I think it not possible.

I have trimmed my "radiator support" almost half way up to be able to squeeze a big intercooler. I have no issues.

I know that where your part is broken that it screws in the front lip of the bumper ( aka spoiler).

I have even cut the inside bracket on the bumper. If you dont want to change the broken part cut it off, or patch it up. Just make sure if you are running the plastic belly pan to secure it so it doest fall off.

I will insert a photo when I was mocking up the IC position, so you can see how far up I have trimmed the plastic radiator support and no issues at all.
IMG-810a975b401c0679addcb0d692984493-V~2.jpg

IMG_20210707_191609~2.jpg

I personally think if you cut or fix that part you wont have any issues. But if you want a perfect car change the whole thing.

Well just priced it with dealer for a brand new panel.... guess what?!?! £250 I am fixing the car on a budget and it will have a massive impact when it will come to sell it.

Think I am going to have a go at plastic welding. Every used frame on ebay is either cracked or broken. Seems like a design flaw imho. There are replica parts which I don't want to invest in as I already had a bad experience with replace headlight bracket.

So as you say, the radiator doesn't rest on it entirely?

[amer6R]

Go ahead weld it, add pieces of wire to make it stronger.

Yes the bottom part doesn't matter, there are bolts from the side that tie in the cross beam to the radiator support and in your case these points are not damaged.
It will be all fine.

That part probably broke because something hit your bumper and pushed it in a little bit.

Make sure that the pipes for the condesor that are behind arent damaged this ( or your AC wont work)

[POLOZ]

Go ahead weld it, add pieces of wire to make it stronger.

Yes the bottom part doesn't matter, there are bolts from the side that tie in the cross beam to the radiator support and in your case these points are not damaged.
It will be all fine.

That part probably broke because something hit your bumper and pushed it in a little bit.

Make sure that the pipes for the condesor that are behind arent damaged this ( or your AC wont work)

Yeah ordered the kit on amazon so will keep me busy on the weekend

Will post back on how I get on with it.

[POLOZ]

@amer6R do you know how to replace the drive belt in a 1.2?

[amer6R]

I don't know, i have never tried it. Under useful parts there is a link for ELSA WIN online there you can find the procedure. You will need a special tool to lock the cams and crankshaft in TDC.

Im currently re-newing the whole front end, bushings, joints, drive shafts...