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Meta87

Member Since: 05 Aug 2022
Location: Innsbruck
Posts: 22

Replacing Headlight Panel

Hi,

I‘d like to replace my wing‘s headlight panel because it’s damaged. I‘m having kind of a struggle figuring out the best procedure. Do I need to drill out all the marked spot welds or is it done by simply drilling out the 2 rivets and unbolting the 3 screws to the top?

As always, thanks in advance!

Click image to enlarge

3rd Nov 2024 8:06am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17318

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Spot welds too, unfortunately.

Land Rover could have made it so easy but didn't.

3rd Nov 2024 8:26am

ibexman

Member Since: 13 Dec 2008
Location: Essex
Posts: 2945

It’s easier to replace the complete front panel

3rd Nov 2024 9:49am

Dinnu

Member Since: 24 Dec 2019
Location: Lija
Posts: 3402

2012 Defender 90 Puma 2.2 CSW Santorini Black

How badly damaged is the panel?
As BW stated, the spot welds need to be drilled. Although never replaced one, I think normal rivet heads replacing the spot welds will foul with the grille panel. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black

3rd Nov 2024 11:02am

Meta87

Member Since: 05 Aug 2022
Location: Innsbruck
Posts: 22

Oh man, I already anticipated these answers. It could have been easy

So I should probably use countersunk rivets.

3rd Nov 2024 12:09pm

Will@LRW

Member Since: 04 May 2019
Location: UK
Posts: 177

1997 Defender 110 300 Tdi CSW Alpine White

You'll also find that there is a "skirt" on that headlamp panel that holds the inner wheel arch, which needs to be removed from the old panel and added to the new one. There is no part number for this part and it is only available when buying a complete wing. LR Workshop
Find a Defender's history and spec: https://defender.lrworkshop.com

3rd Nov 2024 9:10pm

NickMc

Member Since: 01 Oct 2014
Location: Norn Iron
Posts: 1620

Yes you have to drill the spot welds out. I’ve done a fair few over the years. It depends how fussy you are and you can also use panel adhesive- following the instructions is very important that way though. TIG weld it, Counter sink rivets too, or you can
buy the front panel complete with the headlight mounting panel already attached.

I’ve also hammered and pushed a few back out, better to start with it still on the car if it’s a larger bit of damage.

4th Nov 2024 8:14pm

Meta87

Member Since: 05 Aug 2022
Location: Innsbruck
Posts: 22

Thanks for all the insights. I have the option to get a full replacement wing without the outer panel but it'sa 300 TDI‘s originally. Will it fit on a TD5? The „vent hole“ is obviously missing but this could be easily cutout.

4th Nov 2024 8:23pm

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