see attached pic. The left arm is normal, where the right arm somehow broke. WTF do i do now?

broken

 

Ouch… thats cast right into the projector.. you have to replace the entire projector to fix that but that means baking and taking the headlight housing apart.. you might need a band aid fix that will be permanent if you dont want to do that.

 

what would you recommend?

 

Use some JB weld and build back up that area. You can dremel a new notch that the clip can slide into. You would have to bend the metal ear slightly so it slides and locks into the JB weld replacement area so it stays firm. Old trick used for years with broken projectors. If the piece was larger, I'd say JB weld that on also!

 

You need to copy the section in red, scuff up the area in orange and clean well to prepare for JB weld. Mix JB weld and create a blob that's secured on multiple areas to ensure it doesn't break off. You'll want to unlock the bulb clip and move it out of the way + put in old bulb while applying JB weld. Remove old bulb in case you have an accident and smear JB weld on the bulb area. Clean old bulb, clean JB weld, reapply and make sure the blob of JB is where it needs be. Having the old bulb in makes sure you don't drop anything into the projector. Plus you don't want to get JB weld on a good bulb and ruin it... Old bulb + removal ensures the bulb is removable.

Get the dremel out (with the bulb in) and cut a small notch for the clip to slide into and lock. Bend clip as needed!