Volkswagen MK5 Jetta Headlight Dust Cover

thingiverse

I acquired a Volkswagen Jetta MK5 from a relative and stumbled upon an issue during routine maintenance - one of the headlight dust covers was nowhere to be found. Without this cover, water seeps into the headlight assembly and corrodes the electrical connections. After scouring every nook for a replacement, I decided to recreate the part as a learning exercise since I was getting familiar with FreeCAD. I intend to craft a gasket out of spray foam to fill the channel around the outer ring for a proper seal. **Edit: Version 1.1 has been added, featuring a slight angle to the outer wall of the gasket slot. The original design fit, but I had to apply considerable force to stretch it onto the mounting surface. This updated version should fit with much less effort.**