tips for headlight glass swap

[sawman]

Any tips from those who have gone before, and to hopefully smooth my journey?

I need to swap out my nearside headlamp lens of my standard '96 400.

I have located the wingnuts via the grill, and hopefully managed to squirt penetrating fluid in their general direction,
I'll come back later and see it they are sufficiently freed. Its a bit of a tight access, so wondering about pulling the cold air feed- or is it doable without shifting it. (so then I am thinking if I have pulled that out I could replace with ACT hose kit !!)

I know about the blob of sealant at the top, and I have a big tube of sikaflex 291i from a recent boat mend, so should be ok putting things back together. I have read that there might be a rubber seal in there somewhere, but I cant imagine its needed with judicious use of the sikaflex.

[sawman]

Close to admitting defeat with this, soaking one of the rusted wingnuts in penetrating oil all day yesterday - no dice so far - will have another crack today. If my bruised fore arms will take it. The inboard wingnut came off nicely!

[Steve_D]

Normal access is via the access panel in the front of the wheel well. Even easier if you remove the wheel first.

From there you should get better access. Breaking the stud is a strong possibility but not a major issue as replacement studs (bighead Stud) are readily available.

I'm confused why you need to replace the glass. The reflector on the other hand is a common problem.

Steve

[sawman]

Glass is broken - stone chip ages ago has finally progressed. I thought the access panel was just for bulb change/ height adjustment screws. I can get my hand on the wingnut its just stuck fast with rust. will the access panel allow me to get a tool on it?

[bobfather]

I had a rusted wingnut several years ago. I just turned it until it sheared off. Once the shroud is off you can bond new bolts on. TVR parts suppliers sell them, just a threaded bolt welded onto a flat plate

[Steve_D]

sawman said:

............... will the access panel allow me to get a tool on it?

Yes you can hook a small ring spanner over the wing nut and shear the stud.

The amount of sealant used under the shroud is quite variable so the cover may not come off easily. To avoid damaging the paint take a dead hacksaw blade and grind off the teeth over about 2". Grind a sharp edge square across the end of the blade.
Lift the bottom of the shroud as far as you dare without damaging anything. From the front insert your blade between the underside of the shroud and the top of the glass. Gently pushing the blade up will slowly cut through the sealant.

Steve

[sawman]

Thanks both,
The restorative powers of a cheese stottie and a mug of coffee has helped. Cowl off and just need to clean old sealant off, so that will keep me busy this afternoon