Some of you may remember a thread I started a few years back regarding the complete corroded destruction of the Hella DE foglamps that came stock on my 2001 4Runner. Back then, I contacted Hella about the problem and was promptly sent a new set of lamps, free of charge. A few of you followed my advice and contacted Hella with similar results.

Well the other day I was doing a bit of wiring on the 4Runner and decided to check why the one replacement lamp was not functioning. Lo and behold, it was totally corroded again - leaving a powdery mess of magnesium crap. So, I did what any rational person would do and sent a new email to Hella, with new pics and the original email trail from two years back. I got a very prompt response back and learned that Hella had devised a fix for the problem in 2001 - but Toyota refused to buy the actual solution. The fix is a simple formed metal cover (aluminum or steel) that bolts on to shield the rear of the Micro DE housings from a constant barrage of water, dirt and road salt.

The person I dealt with was kind enough to send two actual Hella tech drawings that show the necessary dimensions and how the shields mount. I will try to post these here a bit later when I have time. If I can find an outfit that is willing to manufacture these, we would have a nice solution to the corrosion issue. Oh, and he is sending out another set of lights next week!

Just thought I'd get this out there for discussion. Also, in case anyone has the right equipment to accurately fab up a set of these, I'll gladly forward the full-size docs that show the measurements and angles.

PICS ADDED AT END OF THREAD!!

Drawing #1



Drawing #2



Andreas

 

In the picture, it seems like the back end of the light is the only thing covered. What about the sides? Can you just manufacture something to cover all sides but leave a couple of holes on top so dissipate moisture? Just throwing ideas here .

george

 

Good job, Andreas! Maybe you will have to go back and visit the guy who helped you with your light brackets. He does nice work.

 

I too had this problem and just recently contacted Hella with the complaint. I appreciate the post as they told me how to fix the problem, sent me two new lamps, but not a diagram.

Apparently the sides don't matter because the violent spray of water is comming from the tires directly behind the light. You can buy the metal at home depot, cut and bend it to fit. I have done similar fabrications like this before. I am planning on doing this in the next couple of weeks and I will try and post pictures of my solution.

Kinda shot my faith in Toyota!

 

Andreas - can you post the contact info for hella? i have notice my functioning light is corroding - maybe i can get a replacement for the broken one too.
thanks.

 

I think this is the issue. Rather than encasing the entire light, Hella just wants the rear to be shielded from direct spray. Incidentally, the two holes in the rear of the shield are probably for the aiming screw - by putting two holes in the design, the same shield can be used on either side.

I would be leery of encasing the entire lamp housing, as they put out quite a bit of heat. I will probably form these shields myself from sheet aluminum - paying a fabricator for this job would probably be prohibitively expensive.

Andreas

 

Folks, there are a few things that you can do before you dump the corroded fog lamp.

1) Change to new Wiring Harness (#87212) which is good for TWO lamps = $22.71 - this will fix most corrosion cases.

2) Change to new housing (#74528) each = $49.25 - this is only necessary for extreme corroded situation.

3) Coat the interior surface & contacts w/ marine use white electrical paste = $5?

4) And of course the much needed splash shields! Thanks Andreas!

(you can get the 1st 2 Hella items from rallylights.com, or if we have enough interest here, I can bargain w/ them for a better deal for all of us, let me know)

Edward

 

I finally got around to having the proper shields made. These are made from 2mm aluminum sheet and have been formed and drilled to the exact specs provided by Hella. I sent the CAD drawings to a buddy of mine in Iceland and he had these made within a few hours. Then I had to wait until he came through here on a business trip last week

Here are the pics:





Andreas

 

Whoa, nice work. You have some pretty good buddies, Andreas!
Now you just need to find some time to get those on

 

I thought you're coming by and doing that for me?



Andreas

 

I want some!!!

 

I am sure we could arrange that




What is with the midlife crisis vehicle???

 

Gimme a few months....

Andreas

 

Waiting on something else from Iceland, are we?

Chris

 

Negative, negative. Just a long list of items yet to be completed around the house....

Andreas

 

Something like this one?

 

No, wait; you said 1998, how about this:

 

Easy on the pipe there, homes...

You're close, but I'm thinking something along these lines:



Andreas

 

So when are you going to start selling these? how much?

 

The Porsche or the splash shields? I don't think he is going to sell either one, but I guess we will have to wait for the man himself to answer...