Integrated turn signal fix...

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Nelsonmd
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Joined: Wed Nov 16, 2011 4:35 pm
Location: Albuquerque, NM

Well my left turn signal stopped working on my bikemaster candy drop mirrors. I figured the wires probably twisted off the circuit since they are thin and spin when you put the mirrors on, so I did some careful surgery on them and managed to disassemble them.
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The lens assembly was glued to the metal housing, so I had to carefully pry it off, and managed to do it without damaging it at all. It was also glued shut, so I had to use my dremel saw attachment to saw around the parting line and crack it open. I managed to do that without cracking anything, and pulled the circuit out. This is possibly the worst circuit I have ever seen.
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And these were taken after I washed and cleaned them. There are so many problems, I don't even know where to start:
1. The solder joints on the resistors are terrible and the resistors are borderline tombstoned
2. The resistor pads are poorly designed
3. The LED joints are poorly soldered, and have been cleaned up with clippers
4. The solder mask is delaminating from the board
5. The wires are soldered to surface mount pads, not through holes

I am contemplating just making a new circuit. It would cost about $50 for both sides to get a professionally fabbed board and populate it myself with more and hopefully brighter LED's, but I decided that is more work and cost than I want to spend and I am going to try fixing these circuits.

My plan is to take it to work and clean it, fix some of the solder joints, and solder on some new wires. Also, I will add some kind of stress relief to the wires to prevent them from twisting off again. I am not sure yet how I am going to reassemble the mirrors, like what kind of glue to use to mount the mirror again, I though maybe some RTV.
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