Installing slimline backside headlight covers on 2001 Ultima

[2001ultima]

My 2001 Ultima is set low and as much negative camber possible. This caused a problem over the years for the backside head light covers. The tires eventually rubbed holes in the original covers and against the back of the actual light assembly. This caused dirt/dusk to get behind the outer light covers. As part of the headlight restoration, I bought a set of the slimline backside headlight covers and they didn't fit. I exchanged information with Ultima and it was identified that my upper headlights were not trimmed as they are currently provided today. Ultima recommended to cut the two upper light housing back flush and bend the light bulb terminals 90 degrees to create the space needed. I followed the recommendation and this solved the problem. My tires no longer rub and the cover doesn't get disturbed.

Photo of head lights prior to trimming, see that larger light lower left wear from the tire.



Another photo prior to trimming.



Measure the depth that you can cut down and then make a cut line on the out side of the housing..



Tape holes to keep dust out and prepare to cut with the Dremel



Pre-cut on line and then check. You don’t want to cut too far down.



First light complete. Rings removed. There are two layers of aluminum to cut through.



Second light complete



Blow dust out, clean any remaining dust and reinstall.



Bend the light bulb terminals 90 degrees and reinstall the wire.

[k wright]

Awesome, thanks for taking the time to document this. Did you replace the silver backing plate after you trimmed the brown drum portion of the light?

Performing this will definitely decrease turning radius and reduce the available space for wider front tires.

[2001ultima]

k wright said:

Awesome, thanks for taking the time to document this. Did you replace the silver backing plate after you trimmed the brown drum portion of the light?

Performing this will definitely decrease turning radius and reduce the available space for wider front tires.

Ken, No. I didn't replace the silver backing plate. That is what is exposed after trimming away the lip/ring. It looks new in the pictures but no that is original. Jim

[k wright]

This needs to be a sticky reference.

Thanks for taking the time to document this.