Headlight installation

[San Diego GTR]

I'm installing the headlights and find the build manual a little light on detail. Did anyone notice a tight fit for the 2 lights mounted on the common bracket? I seems to rub on the top against the body. I presume the rubber gaskets are to be mounted between the light housing and the body. Is that right? Also, the turn light is larger than the precut opening and stands back from fully going into the hole about 3/4". Is that right or does the hole need to be enlarged?

Thanks guys,
Paul

[steve_d]

San Diego GTR said:

I'm installing the headlights and find the build manual a little light on detail. Did anyone notice a tight fit for the 2 lights mounted on the common bracket? I seems to rub on the top against the body. I presume the rubber gaskets are to be mounted between the light housing and the body. Is that right? Also, the turn light is larger than the precut opening and stands back from fully going into the hole about 3/4". Is that right or does the hole need to be enlarged?

Thanks guys,
Paul

Not sure what you mean by 'Gaskets'. The plate the two lights are mounted on are fitted to three studs (threaded rod) About 5/16" piece of 1/4" rubber tube is cut and placed on each stud then the light plate. By winding the nut down you compress the rubber tube which gives you the required headlight beam adjustment. You may need to experiment with that 5/16" length.

Think we need pictures to help you with the turn light.

Steve

[San Diego GTR]

Thanks Steve. I've posted some pics here:

http://homepage.mac.com/quailpark/fil
http://homepage.mac.com/quailpark/fil
http://homepage.mac.com/quailpark/fil

I think I've figured out the pair of lights, but the size of the turn indicator is wayyyyyyyy off from the hole drilled by the factory.

Any ideas? What am I missing?
Paul

[crafty]

San Diego GTR said:

Thanks Steve. I've posted some pics here:

http://homepage.mac.com/quailpark/fil
http://homepage.mac.com/quailpark/fil
http://homepage.mac.com/quailpark/fil

I think I've figured out the pair of lights, but the size of the turn indicator is wayyyyyyyy off from the hole drilled by the factory.

Any ideas? What am I missing?
Paul

You're missing elbow grease - I needed to open up the hole for my indicators too..

[San Diego GTR]

Crafty you're probably right on the elbow grease, but how do you secure it? I just have button head bolts and nyloc nuts in the kit.
Paul

[davefiddes]

The Nylocks are for securing the glassfibre outer cover to the studding. The button head bolts screw into tapped holes in the surround. You'll need to drill and tap these yourself. Seems a bit alarming but it works very well. I had to do quite a bit of careful sanding to open up the holes for the various lights especially the indicators.

[crafty]

For the indicator lights, I epoxied the bolts to the fibreglass headlight housing.

[mkoch1]

I riveted the light to the metal plate, then used revnuts to secure the plate to the housing. I also had to do a bit of grinding on all the lights to make them fit.



mark

[San Diego GTR]

Thanks Mark, That is the way mine looks now, but I'm nervous about mounting the indicator light to the body. Is there enough of a void in there to use a revnut? Richard just emailed me and said to thread the fiberglass. I can only assume these two techniques DO NOT show through to the front of the car. Is that right? I'll need to bite my nails some more on this one.....

Paul

[mkoch1]

I used pretty small rivnuts and there was enough of a void. Just drill slowly so you don't break through to the front of the housing.

mark

[San Diego GTR]

Got it guys. Thanks for the advice. They look great now that they are in.

Paul