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Community Manager

Community Question: Things you never knew you needed to weld?

I am showing my age with this question, as I'm sure this happens regularly to those that switch out sealed beams more often than I have over the years.  But these stainless steel(?) headlight are easy to break, especially those with a spring (i.e. the hole on one side) that puts a lot of tension on the whole thing...which isn't great after 48 years of use!


That said, I learned how to PROPERLY remove these (with a hooked tool to release the spring tension FIRST) but it was too late and I needed my neighbor to weld 3 of them back together. He's pretty good with a MIG, as this metal is super thin. 

'72 Mark IV headlight ring | Sajeev Mehta'72 Mark IV headlight ring | Sajeev Mehta


SIDE NOTE: I still can't believe how rare these particular trim rings are (only available aftermarket if you search for 1969 Mustang) and I'm still trying to understand why this was a good idea relative to newer headlight rings that just use 3-4 screws.  


Advanced Driver

I remember having to deal with those way back in the day. They were a minor pain and I asked myself the same question...why?

The only thing I ever came up with is that with time and corrosion those little screws (on the rings that used them) occasionally didn’t like to come out and the heads would strip.

And tell your neighbor I’m jealous. In addition to the equipment, apparently TIG requires coordination, practice, a steady hand and intelligence enough for a passing knowledge of metallurgy. Who knew?

Community Manager

Yeah I can't believe he managed to weld these up with a MIG, I will tell him of your kudos! 


I gave him three and you can tell which was the first one he worked on: not as pretty but it got the job done.  Actually only I can tell, as I know which headlight to look at (which I won't do that because who cares about an ugly headlight ring!).

New Driver

Sajeev's neighbor here.  I will admit that I was surprised that I could weld these.  Thin metal with MIG can be tricky.  I cranked the heat all the way down and still blew a hole in the first one but the other two turned out decent.  As Sajeev stated, all 3 were functional and given how they are installed, you will never know which one has the hole in it.  I might have to get a TIG one of these days if Sajeev keeps giving me these funky projects. 😁

Community Manager

I will never be the reason you buy more tools.  That said, you should get a TIG. 


I have been lucky. I can stick weld but my father in law could weld plastic to cast iron if asked. 

Seriously he is one of the best welders I have ever seen. 

i have an air dam that makes my car difficult to load on a flat bed or in danger if I autocross. I decided to use two stainless plates with six small stainless nut welded to them. This would make it so I could use the places to screw the air dam into on the lower side of the cars nose. Makes a 1 hour job into a 10 min job. 

He welded these nuts perfect stainless to stainless. And these were not large nuts either. 

Now we do need a story on what have you fixed with JB Weld. I bet there would be some amazing stories. 

Community Manager

Oooh, a JB Weld story is a great idea. 


I can stick weld, and was given a wire feed for Christmas one year. I am still working on that. I'm getting better, but I wouldn't DREAM of trying to weld the headlight rings on my Cougar. That being said, if you are ever in the market to buy some, check out West Coast Classic Cougar. They have them for a great price.

Intermediate Driver

"metal glue' I call it. It scans from brazing thru mig, tig, stick and may B ends w/'forge welding". I may use it to remove fasteners (.125 trim screw - 3/4 inch exh bolt) stuck from 40, 50 yrs of  being frozen 3 times a day (tack a bolt head on that baby & wrench it out)...

Pit Crew

How about plastic ? I had a buddy with a plastic welder. The kit had about 5 different types of plastic rods in various colors. It had a sort of soldering gun with a tube running through the middle of it to feed the rod as you heated the repair area. I had to fix a broken electrical housing on my Fiero and it worked perfectly. Harbor Freight has this one >