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Discussion summary
YOUR RESEARCHHeadlight related PSA for 996.2 halogen owners
Leading reported evidence
Use rather than a singular mold
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Just from looking at the parts, it looks like 2 separate molds were used, rather than a singular mold with modular handloads.
Leading evidence: 'Use rather than a singular mold' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Use loctite' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Suggestion
I suspect(ed) it's from using loctite, because they didn't seem that brittle when I took them apart.
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Suggestion · Original poster
I do use red Loctite on all my installs, but never had this issue with the Litronic black brackets....?
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Generation: 20261026T150451Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
This week I'm retrofitting my first ever set of 996.2 halogen headlights. I must have done close to 20 Litronic headlight sets, just never ran across the halogen ones. It seems most 996.2's in the US had the Litronics upgrade.
Full retrofit, meaning new internal harness, Retrofitlab halogen to bi-LED projector upgrade, new outside rubber seals, all LED bulb replacements, lens restoration + PPF, and even blacked out inside shrouds (pictures will follow on this one later).
Reason for my post, however, is not about any of these items being replaced. It's about a part that is re-used in the Retrofitlab install, namely the projector bracket.
Now I've noticed before that the bracket in the halogen headlights looks different from the one in a Litronic headlight. The halogen bracket is made out of a transparent plastic (I assumed to be Polycarbonate - PC), whereas the Litronic bracket is made of an opaque plastic (I assumed to be Polyphenylene Oxide - PPO). Sorry to get all technical, but I used to work at GE Plastics a lifetime ago where these were sold as Lexan (R) and Noryl (R), respectively.
When I proceeded to fasten the new projector assembly to the brackets, I noticed what appeared to be small cracks around the screw holes. I soon found out that this was not polycarbonate, but some inferior thermoplastic that had outlived its useful life...
I had not noticed this in what I like to call my "receiving inspection", a video I make of each set of headlights sent to me, to locate and identify any issues or defects previously unknow to me or the owner. Needless to say, that therefore this is on me, and this is also the reason why I keep a growing "stash" of headlights of the "broken" or "for parts" category on hand in my basement. So the good news is that this customer will get upgraded not only to bi-LED projectors but also to the Litronic projector brackets.
Not bragging or complaining, just thought the community should know about this, especially those with halogen headlights. I'm supposed to be an expert (of sorts) on these headlights by now, and so I will look for this issue on the next set of halogen headlights that I will be retrofitting.
If you are planning to get the kit and DIY it, let this be a heads-up for you. As with many parts in our headlights, they are not available as a replacement part and right now the cheapest headlight you can find on Ebay to cannibalize for ONE of these brackets runs $500. Provided I have some on hand, I promise I will charge you a lot less than that, on the condition that you let me perform your retrofit, of course.
Below some pictures of the two brackets and the carnage I found. Notice in the last picture how the two screws have a nearly perfect "washer" on them from the deteriorating plastic brackets.
I used to work in prototype injection molding, I loved the crap out of that job but unfortunately family businesses don't pay much. That transparent bracket bears the raw color of PEI (Ultem, way too fancy of a material to be breaking like that), but acrylic comes to mind from looking at it. Just from looking at the parts, it looks like 2 separate molds were used, rather than a singular mold with modular handloads. Just goes to show how many of these cars they planned on making (and ended up making in turn).
If you can get the parts laser scanned or otherwise modeled, you can probably 3D print new brackets with Polymaker PLA Pro. My friend group uses that as the standard for printing gun parts. CF Nylon is a lot more expensive but is the overkill option for filament. You would also need to pre heat and dry (4hrs @ 180�F) CF Nylon before processing. The all in cost would still be under a single headlight from eBay.
OP" FWIW, my litronics brackets shattered like the yellow ones. I suspect(ed) it's from using loctite, because they didn't seem that brittle when I took them apart.
Interesting. I do use red Loctite on all my installs, but never had this issue with the Litronic black brackets....?
I'll experiment with these brackets since they are shot anyway, see if Loctite has a negative effect.
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