Cutting access hatch for headlamps

[-JUT-]

Evening all,

Changed the headlamp bulbs on my car today for Osram Silverstars to improve the night driving until I can spare the cash for xenons. I had to do it the hard way as much to my annoyance, my car seems to be one of the ones that has no access hatch to get to the back of the lights.

Does anyone have any pics of the location of the hatch, or if they've cut their own hatch, pics of the work in progress? I'm thinking that I'll use a dremel to cut a panel out, is there anything attached to the inside of the arch that I need to avoid when making the cuts?

Cheers

[biker]

I see yours is a 96,mine is a 95 and to get to the headlamp bulbs all you need to do is remove the number plate and gently prize out the grill then reach in either side to change the bulbs.

[oggs]

Mine is a 95 and the hatch is easily seen in the wheelarch

[ekim]

y old one was a 95 and i did it thru the grill and it wasnt such bad job, my new one is a 200 and has the holes but no idea how you get them out they are well sealed in. i too have just got some better bulbs but keep putting off fitting them

[-JUT-]

biker said:

I see yours is a 96,mine is a 95 and to get to the headlamp bulbs all you need to do is remove the number plate and gently prize out the grill then reach in either side to change the bulbs.

That's how I did it yesterday. But to be honest, I find this method to be a ballache, and also runs the risk of scratching the bodywork should your screwdriver slip whilst working the grill out, or especially back in. I'd like the access hatch just to make the job easier if needed in future, plus for when I change to xenons, better access will be nigh-on essential for wiring etc.

[smb]

the hatch was added around mid 96, so if a 95 model has it, then it was added at some point in the past, in theory they shoul dbe easy to add, cutting a new hole and adding a cover, screwed and sealed over the hole.

[-JUT-]

smb said:

the hatch was added around mid 96, so if a 95 model has it, then it was added at some point in the past, in theory they shoul dbe easy to add, cutting a new hole and adding a cover, screwed and sealed over the hole.

Agreed - I'm just trying to clarify the exact position to cut, and whether there's anything on the other side of the arch liner I need to make sure I don't cut in the process! Hence the need for piccies of a car that has the access hatch!

[spend]

I thought about this, but decided to keep the strength of the wheelarch intact.

I removed the diagonal struts so you can get into the grill area (later replaced them with removeable alloy stays cos bonnet hinge area flexed a bit) and got rid of the rubber. You can buy cheap edging trim to go round the alloy grill and attach it with screws.

Dave

[sparkythecat]

I jacked the offside up and took some photos for you.

In the photos you will see I've removed one of the hatch securing screws and rotated the hatch cover oout of the way.

The access hatch hole is 130mm in diameter

The hatch cover is 170mm in diameter

The outer edge of the hole is 150mm from the outside edge of the wheel arch

The outer edge of the hole is 280mm from the bottom edge of the wheelarch

There is at least 50mm of clearance behind the access hatch.
(ie. You could cut a hole with a saw blade going 50mm through the wheel arch and not hit anything - at least not on my car. It's a 98 car without PAS)









Let me knw if you want anymore pics/measurements

Edited by sparkythecat on Sunday 7th January 17:43

[-JUT-]

Excellent, ta very much!

[that daddy]

Well done sparky that useful.