I posted this DIY over at evolutionm.net, hopefully this will help those of you with cracked fog lenses...
Background Info:
Both of my fog light lenses cracked about 2 years ago, it happened when the weather started getting warmer after the 2nd winter my car endured. I am 100% sure the cracks were not impact-induced, but in fact they cracked due to temperature changes. Both lenses started cracking about the same time and the surface is completely free of nicks or chips, and the cracks started developing from the inside. I've searched around this forum and clubralliart.com and quite a few people have experienced the same issue, and they all live in either NorthEast or Canada.
Long story short, brought it in to the dealer, service manager agreed with my theory, regional warranty manager didn't and he declined to replace my fog lights under warranty, I walked out pissed cursing at Mitsubishi.
Drove around with the cracked fog lights for 1.5 year, moisture would get in and light bulbs would go out all the time and the lenses look ghetto. Started doing some research and found out people have attempted to replace the lenses themselves. So I decided to go ahead and try it since it's better than paying $100 for a new pair of fog light assembly.
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Tools and Materials Needed:
Pre-cut glass circles 3.5” diameter and ¼” thick
Visit your local glass shops or Google "pre-cut glass circles"; I went with ¼” thickness over 1/8” worrying that 1/8” may be too thin. I paid $5 for each piece.
High temp resistant silicone sealant
I went with this:
http://www.caulkyourhome.com/ge-sili...w-and-door.php, it is not advertised as high temp resistant but that’s the best my local Home Depot had to offer. The temp range listed on the label says -40 to 400 degrees so it should be good enough especially I use LED bulbs for the fog lights which do not produce nearly as much heat as halogen bulbs.
New bulbs if they need to be replaced. I would recommend LED bulbs; they are cheap and look so much cooler. I bought a set from eBay and paid ~ $10 for a set of H11 White LED bulbs with 68 LEDs on each. Do not get the ones with 120 LEDs, the diameter of those bulbs are too big to fit through the opening in the housing (I know because I wasted money on a set).
A philip screwdriver.
A hammer or mallet used with a screw driver to break the old lenses off.
Some working gloves so you don’t cut yourself while cleaning the broken glass off of the fog light housings.
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