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Old 07-28-2012, 11:36 AM   #1
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Alpine Headlight covers


I have a 99 Alpine. Does anyone know where to find a replacement headlight cover????

I had about 2 " of water inside mine, apparntly the small drain was plugged. Did not know a drain existed until I had the cover removed. Only 2 very small bolts plus 5 gallons of windshield sealer hold the cover in place. 3 hours later I finally had the sealer removed from the coach, now comes time to clean the plastic cover. I was using enamel reducer on the coach which was fine, but not on the cover. Where I wiped the sealler from the cover looked like it had been cleaned with sandpaper. It really etched the plastic bad,


I like my Alpine and for the most part I think it is very well engineered, but not the headlight system. It appears that this lens cover must be removed to replace a headlight lamp??? If it were not for the extreme time consuming, messy sealer it would not be so bad. I think when I put it back together, I will use black electrical tape around the inside of the cover and the same on the coach side then use the windshield sealer in a roll with the paper backing . By doing this I think I can make a proper seal and not have such a terrible mess should I replace a head light lamp. Any other suggestions??? best wishes, old trucker
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Old 07-28-2012, 12:19 PM   #2
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I had a '99 and offer these suggestions:
When putting the cover back on, seal only the upper part. That way, if the drain holes plug, the water can still drain from the bottom.
Also, take the cover to a plastic shop and using it as a form/mold, have them make a new cover blank of Lexan. Drill the holes when you get home.
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Old 07-28-2012, 09:17 PM   #3
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You can always leave the cover off. It doesn't really do much.
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Old 07-29-2012, 08:01 AM   #4
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I bought rectangular sheets of polycarbonate the same thickness as the original and slightly larger length and width. I used the old lens to build a form, out of scrap plywood with the same curvature as the original lens. I then used a heat gun to shape the poly rectangle around the form. I then cut the rectangles using the original lenses as a pattern. I used foam weather striping with adhesive on 1 side only. Now I can easily remove and replace the lenses. I also added a few more screws around the perimeter of the lenses to hold them securly in place.
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