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I needed to remove the headlights on my 1990 240 to replace a header panel.As usual some of the bolts were rusty and started spinning in the buckets.I took a sawzall to them to cut them off.Once I had them off of the car it was time to replace the bolts.I could not find the same size head in stainless so I went with the next size in dia. and length.I reamed the whole a little larger.I mixed some 2 part epoxy and made a puddle in the bolt hole.I then wrapped the bolt threads with tape and pushed it through the whole.On the other side I epoxyed a stainless washer for more support.My lights are E-codes so the glass is held in place by 7 clips.The hardest part was trurning the little white cone clips that holds the reflector in place.Slow and steady wins although I did snap a corner of one.Note I also put more epoxy on top of the bolts to make it very stiff.DON"T FORGET TO WRAP THE BOLT IN TAPE!I emphasize this because I didn't do it the first time.That's right had to do the job twice.Although I cleane off the thread some remained and I could not tighten the nuts,bummer.Also wait 24hrs for everything to cure.One of my bolts did not set up properly.Hope this helps.Follow link for pics.
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