XK8 / XKR ( X100 ) 1996 - 2006

Roof Console Repair

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Old Apr 4, 2021 | 06:05 PM
  #1  
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Default Roof Console Repair

As mentioned in an earlier post, after hitting a major pothole my roof console cracked it's mounting bracket and was hanging by the wires. Only one spring clip remained intact and connected to the housing. After much searching on Ebay and many other online sites, salvage yards, and even dealers, I was unable to turn up a matching color used one and just couldn't stomach the $1400 to $1600 dealer price for the entire assembly. All my electronics were fine, I just really needed a new plastic housing that had the tabs for the metal spring retaining clips intact. No such luck.

The mounting bracket itself was fairly easy to find. I suspect they must break quite often. It was only $13.35 delivered. Part number HJA2057AB from Engle Imports.

So after I did a zip tie replacement for the rear center spring clip that seems to work well, I decided to make a metal replacement tab for the spring clip to grab onto. I made an index card template to cut to fit and then scribed that onto a thin piece of stainless steel strapping. Cut it out, adjusted the fit and epoxied it into place. Once the epoxy dried, I put the LH spring clip back in place over the stainless strip. It bites into the stainless really well and seems quite firmly attached. I also replaced the lights bulbs while I had it down. Once all the clips were back in their proper positions, I reconnected the wiring, lined the clips up with their respective slots and with a little finagling, it popped right back into place. Seems secure but some actual road trips will tell the tale. Hope it might help someone that finds themselves in a similar bind. I was surprised that the garage door opener didn't need reprogramming.
A few pics that might help explain it better.

Rear center spring clip zipped in place

Paper template and stainless tab

Stainless tab roughed up for epoxy

Stainless tab replacement test fit

Spring clip on stainless tab

 
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Old Apr 5, 2021 | 07:00 AM
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Well done....
 
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Old Apr 5, 2021 | 07:45 AM
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Great Job! That must have been some pothole???
 
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Old Apr 5, 2021 | 11:18 PM
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Indeed it was. Took it for a 50 mile spin to the tire shop today and the console repair is holding up fine so far. I wish that was the only damage caused by that dang pothole! Verdict is not good from the tire shop after they got it on the alignment machine.
 
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