First let me say thanks to Cruiser Jimmy and all the others that contributed to this thread. Without your advise I would not even attempted this.
And to the first person that tells me that I have over-engineered this, yes I know. It is a sickness. My father is an engineer and it is in my blood. I cannot help myself.
My mirror had all the same problems mentioned here PLUS it also had a busted mounting post. I fixed both at the same time using this process.
First I used the mirror bracket as backing and support to create a mold using painters tape. This worked well and the 'ears' came out quite symmetrical.
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Then I used a ZipLock to mix the JB-Weld together and cut a corner off like a cake decorators bag to fill the mold.
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Once the mold was filled, the JB-Weld dried, I inspected the contact surfaces. I was not pleased with the adhesion, so I decided to add some fiberglass to the back and another thin coat. The thickness does not matter as I will explain later.
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Two small pieces of fiberglass, add some JB-Weld and poof! A much stronger bond.
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I sanded everything down so it was flush and symmetrical.
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Sorry for the blurry photos, my camera phone was acting up...
Using the mirror bracket to determine the location, I carefully drilled several holes and used a knife/chisel to open it up into the form of a slot.
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Then I carefully drilled a hole through the 'ears' for the pin (nail) that would be used to grab the 'hook' on the tabs of the mirror bracket. Once fit and tested, a little JB-Weld to hold them in.
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Hopefully it will hold up a bit better than the JB-Weld alone and is much stronger this way. I really do not want to do this again...
Lastly to my mirror mounting post. The PO had done something to break off the small shoulder at the top that is used to hold the retaining clip.
Using Zip Ties, I compressed the spring (use 3 not two unless you want to watch your spring shoot across the garage at 100MPH). Carefully drill a small hold through the post for a retaining pin (nail again). Put the whole mess together, insert the pin and then cut and remove the Zip Ties.
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I would like to thank the PO for also losing one of the small ball bearings in the base. I substituted a .177 cal BB but be warned it is too small. I was determined to finish up this mess so I just went ahead and used it. It was good enough.
Everything is rock solid now and I hope it will stay that way. Cheers!