alanforn

First off I realize this thread may be worthless without pics however thought I would share my project. Recently acquired a used set of the blue zoom side mirrors from a forum member (thanks Mark!) I wasn't particularly happy with the idea of taping over the existing mirror. Looking a bit deeper I determined that I could probably modify the black housing that holds the stock mirror to accommodate the slightly larger zoom. First I removed the stock mirror (pop off from bottom) and layed the zoom over the stock, you will see the zoom is a bit wider in height top to bottom. After looking at the back side of the black housing I determined I could cut off the bottom third of the housing with a dremmel cutoff wheel. I avoided the mounting tabs so you'll end up with a somewhat narrow piece of the bottom housing. I attempted to remove the stock mirror it broke, CAUTION- as carefully as I tried I ended up shattering the piece, a white sticky white caulk like product is used and holds the mirror quite well. You may be successful getting it off, I was not so be sure to wear gloves, glasses and be wary of fragments that may get away. Once cut, mirror removed, all white caulk removed (worst part of job) I was left with a clean black housing with bottom removed and my new zoom. Placing the mirror into the lipped black recess and placing the removed section back on will show you the new size required to make it fit nice. Also take this opportunity to place a padded sticky in the middle to eliminate the concave portion of the mirror, there is a "witness hole" on the back of the housing you can use to see how much you need to pad out the center. I chose Permatex plastic welder (black) as my adhesive, it worked really well. I placed a small piece of tin foil to allow the mirror to release once I applied the glue at the cut, the cut portion will now have a gap which will need to be filled and glued. I placed the zoom glass in the housing, placed the cut piece at the bottom and taped everything together using painters tape. Basically you are using the zoom mirror as a template to make the new size required. Once that's done mix up the glue, place the mirror/housing face down and apply the glue to fill in the gaps on the back side of the housing. Walk away and let everything cure well then remove tape and mirror. Now you may fill in any voids that may left, you'll have some small gaps on the sides (the only part visible when on the car). I filled those gaps (carefully) with the black glue also. Remove any mounting tape that is on the zoom mirrors, since the abs glue worked so well I used it as the mounting adhesive for the glass, lay a light bead back far enough that it won't "spooge" out let dry and reinstall mirror.
This sounds a lot harder than it actually is, I actually enjoyed doing the project and its nice having mirrors that fit perfectly flush and look factory. Hope this helps someone, I get signed up with an image sharing site will surely post pics. Anyone that really wants to see feel free to PM and I'll email.

Alan