E53 DIY visor repair
 

Both of wife's visors snapped in half at the bend. They are $130 part @ Amazon. Or $7 and a 3 hour round trip to the nearest pick n pull (if they have it: they won't check).

So I'm fixing them.

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I cut down a pex elbow (2 for $3) to use to replace the busted elbow. I cut the inside corner open so I could solder the wires back together.

PC-11 epoxy but it cures so slow I'm going to use JB weld or scotch weld 3M for the other one.

I forgot to take a pic of the solder job I'll try to remember on the second one.

The first pics show how I cut a bevel on the bottom of the retaining post so I can remove. I may need to add a circlip to hold It on but probably won't need it.

And finally: I figured out why they they both broke within a month or two of each other after 17 years:

The internal grip that is designed to keep the visor out by the door developed too much friction and the torque put way too much axial stress on the elbow. I will try to get a measurement of the torque before and after fix. (I will be putting a drop of oil to reduce the torque on mine before they both self destruct as well).

Creative. But I think would have ebay'd for replacements.

eBay are about $100/pair but also 10 years to 15 years old so will be quite likely ready to break. Neutron embrittlement makes it all ready to snap.


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Didn't realize they were so pricey. You may be right about the brittle nature. But I've only seen that break on one or two cars. E39 comes to mind. I'm not sure how common a failure it is?

Either way. You got it handled. :thumbup:

Nice job!

So I just finished the second one. It was far easier the second time. About 75 minutes start to finish. I realize time is money but I also hate throwing away something that just needs repair it's my nature. Also with TWO OF THEM I just saved enough to take the wife out for a nice dinner.

Here's the best part though: I've determined the exact failure mode so others can hopefully just avoid breaking theirs.

The plastic on plastic bearing sureaces develop too much friction and the torsional stress is just too much, it sets up a fatigue failure and it snaps. One drop of oil in the right place will eliminate the chance of snapping the visor in half. I'll see if I can get some before and after force measurements so people can test theirs out.


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Nice fix !

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Showing the solder job

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This connector opens easily by sliding the black part over.

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Impossibly short torn wires. Getting these out and separate is the most difficult part is job.

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Cut down to fit into the brass elbow.

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Drilled out the elbow to 3/8".

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Cut the inside corner of the elbow

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I would agree with Crystalworks. There are so many available from Ebay. Take your color and pick.