Fixing a Cracked Partitioned Lens

24. November, 2012 Lenses No comments

Fixing a Cracked Partitioned Lens

Alright, so you just broke the original lens to your shiny just-painted classic ride, or you are slightly less unlucky and someone else broke it. Either way we cant leave well enough alone, lets take this ugly lens and make it invisible again! In this tutorial we’ll be Repairing the cluster lens from a classy 1968 Dodge Charger! The issues confronting us are a break, and crack.

What you will need:
  • Band saw
  • Belt sander
  • A dremmel with a plastic drilling/cutting bit
  • Super glue or similar
  • Scotch and/or masking tape
  • Piece of paper
  • Padded clamps
  • A clean work area free of dirt and dust
  • Plexiglass or similar of same thickness as original lens


Step one

To address the crack in the lens, we will be cutting out the old one, and replacing it with new Plexiglass. To start this, clamp your cluster lens down, use caution, because your cluster lens is old plastic, thus VERY brittle.

Step two

When cutting out the fractured plastic, be sure of two things, clarity (don’t cut where you would see on the finished product), and, safety for your irreplaceable part, more importantly your own safety (wear glasses, and ear protection), use a dremmel certified for cutting plastic, and DO NOT RUSH.

Step three

We had a crack which looked pretty flimsy; so we wrapped it in masking tape to keep it from moving too much. Use a sanding wheel on the dremmel to round out the circle (or whatever shape) just right.

Step four

Use the hole you just cut to trace onto your new plastic.

Step five

Use a band saw, and cut about a blades width outside the line you just traced, you can always take more off later, so cut the replacement piece so you know it’ll be a bit to big, we’re going to sand it to shape anyways.

Step six

Rotate the new piece around a bit, till you see where it would fit the best, you want a tight fit; use a sander to sand it to shape.

Step seven

Once the piece fits, remove the paper covering from the new piece, and put it into place, use masking tape on the front to hold it in place, make sure the front of the new lens portion is as flush as possible. Super glue the lens in place on the back side (opposite your tape; be careful to not get any on the visible area)

Step eight

Final result, looks great, and you’d never know it was repaired!

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