996 Headlight rubbers..... how hard can this be!!!!

[peterzoom]

The rubber/plastic seals that form the join between my 996.1 C4's Litronic lamp units and the wing are turning into a semi liquid jelly. No problem I foolishly thought, as there was a part number on the offending items.
A quick call to my super helpful OPC parts department and the bad news that this item is not available as a separate part. The only way to replace them through Porsche is to purchase a pair of brand new lamp units. Not exactly cost effective, don't look at the price of these lamps, your heart will stop. The parts-man did comment that my request was quite common
The other option is to seek out a pair of good used items from maybe a Boxster, however having had a look at loads they all seem to have more or less the same degradation, so not much luck there.
Next I emailed Bosch, who manufacture the units. After much back and forward shuffling from one department to another I finally got a definite and emphatic NO from Bosch.
I wonder if anyone has any other ideas or leads that might help me secure a pair of these seals or perhaps be able to pass on to Porsche that these items really should be available as a stand alone part. Honestly, how difficult can it possibly be for the manufacturer to provide these items ????

 

[T911UK]

Bosch stopped making lighting 7 or 8 years ago. Automotive Lighting make most of their stuff now but that doesnt really help you as they wont sell the seals either!

 

[wibble]

Depends how resourceful you are, but I would look to fabricate my own. If you try some of the US forums such as rennlist, usually someone had found a solution or you may even find a supplier.

 

[peterzoom]

Thanks for the tips but even in the U.S. they have the same problems and no solutions.
The seal itself is quite a variety of curves/folds/contours and channels so fabricating from stock components is likely to be a bit Frankenstein's monster in appearance.
It just seems odd that a body seal is not available especially as it has a part number embossed onto it and it is by all accounts a common requirement.

 

[Jon_Dakeyne]

What's the part number? A friend of mine had some Alfa windscreen rubbers made for his Montreal as they are no longer available so I might make enquiries as to how costly it would be to get a stock made if we're all going to need some sooner or later.

 

[peterzoom]

That would be really helpful John. The part number is 996.631.172.00 for the right and Part number on the left one is: 996.631.171.00 . So that is the seal for the 'fried egg'' type of light assembly.

 

[wibble]

That is a shame. Keep us updated.

 

[thirteeneast]

With the cad file could they not be 3d printed in rubber?
If you have no access to a 3d printer many places online price per print and are very reasonable, but then printers are fairly cheap too.