Headlight Replacement
Discussion
Has anyone sucessfully managed to replace their pop up headlights for a static setup that "works"? I looked at this years ago but never got round to doing anything as at the time the smallest diameter light unit was 90mm dia and a pair wouldnt of fit in the wedge cutout with all the framework etc.
Now Hella have their 50mm units, I was wondering if anyone had tried it?
Regards
Iain
Now Hella have their 50mm units, I was wondering if anyone had tried it?
Regards
Iain
http://www.pistonheads.co.uk/gassing/topic.asp?t=4...
Been discussed before. I still have some Fiat Coupe headlights that I might saw up to see if they can fit but the whole rebuild project is awaiting free time to start it. At least I have the garage now but won't be advertising any pop up headlights soon.
Been discussed before. I still have some Fiat Coupe headlights that I might saw up to see if they can fit but the whole rebuild project is awaiting free time to start it. At least I have the garage now but won't be advertising any pop up headlights soon.
I do wonder whether the old TR7 motors could be replaced with vacuum actuation. Lighter, and with a vacuum accumulator (a blow-moulded Polythene vacuum reservoir that looks like it was modelled on a bunch of oversized snooker balls) such as those used on most recent cars (BMW E34 M5 and Porsche 928S4 onwards to name but two) with vacuum operated variable length intake runners it could work pretty well. Of course you'd need to source/manufacture the actuators. Now, wheres my Lego Technic pneumatics spares catalogue...?
Well done I can wait now to see how your effort works out. Are you going to extract the headlights and make new fittings or use the base and cut bits off?
It seems that only that part in front can be sawn off and a hole would need to be cut in the bodywork to allow access to the bulbs from the rear and then the bonnet gets in the way.
I have thought that the whole headlight fitting could be made to fit onto the bodywork but might just look a bit cross eyed. I haven't had time to take a pod out yet and experiment. It will be interesting.
The minimum headlight height seems to be 500mm from the bottom of the reflector.
I got my idea from here. It's also where I realised the cross eyed bit
http://www.euro-nova.co.uk/phpbb/viewtopic.php?f=1...
It seems that only that part in front can be sawn off and a hole would need to be cut in the bodywork to allow access to the bulbs from the rear and then the bonnet gets in the way.
I have thought that the whole headlight fitting could be made to fit onto the bodywork but might just look a bit cross eyed. I haven't had time to take a pod out yet and experiment. It will be interesting.
The minimum headlight height seems to be 500mm from the bottom of the reflector.
I got my idea from here. It's also where I realised the cross eyed bit
http://www.euro-nova.co.uk/phpbb/viewtopic.php?f=1...
Dunno yet, I'll see how things pan out when I get the lights- I'm running adjustable coil overs so may have to have an MoT ride hight 
that said they susally struggle to get the jack under when they put it up on the 4poster to check wheel bearings etc, so it may come as a bit of a relief for the tester!
Regards
Iain
that said they susally struggle to get the jack under when they put it up on the 4poster to check wheel bearings etc, so it may come as a bit of a relief for the tester!Regards
Iain
Hi folks, right I've removed the light pod and had a play with the Fiat Coupe unit. although it seems a nice idea to use the whole unit, the curves of the clear plastic dont suit the car so I've dismantled the unit, easy job, bake at 80oC for 20mins, remove cover, unscrew inner trim, pop off the headlight unit from the adjusters. Simples #tick# (sorry)
I've done some measuring etc. these are for a S1 FHC that sits quite low (im running coilovers) Ground to front lip of headlight void is 51cm. The rear lip of the void is approx 120mm higher, the high beam unit is approx 90mm. So it will fit, quite how I get it to fit is still up for debate, I could set it all back quite deep into the void, but then I'd need to cut a panel in the "bulkhead" where the headlight motors normally bolt through, and rehinge the bonnet. The Alternative is to set the lights slightly further forward and use the emergency headlight winder hole to adjust the beam and change bulbs and while it would come under the catergory of an absolute b
h of a job, it is possible. The plan then is to sit a tray into the void and the base of the lights and run 2off 10x10 strips of ali angle down the sides of the void rececced 3mm to allow some nicely cut polycarbonate to be bonded into place. The real trick is to make some besels for the lens units to make them look "right"
My other concern is that the light beam with refract too much in the polycarbonate, and I'm wondering if the Fiat covers are curved as much as they are to have the light pass through more squre on...
Regards
Iain
I've done some measuring etc. these are for a S1 FHC that sits quite low (im running coilovers) Ground to front lip of headlight void is 51cm. The rear lip of the void is approx 120mm higher, the high beam unit is approx 90mm. So it will fit, quite how I get it to fit is still up for debate, I could set it all back quite deep into the void, but then I'd need to cut a panel in the "bulkhead" where the headlight motors normally bolt through, and rehinge the bonnet. The Alternative is to set the lights slightly further forward and use the emergency headlight winder hole to adjust the beam and change bulbs and while it would come under the catergory of an absolute b
h of a job, it is possible. The plan then is to sit a tray into the void and the base of the lights and run 2off 10x10 strips of ali angle down the sides of the void rececced 3mm to allow some nicely cut polycarbonate to be bonded into place. The real trick is to make some besels for the lens units to make them look "right"My other concern is that the light beam with refract too much in the polycarbonate, and I'm wondering if the Fiat covers are curved as much as they are to have the light pass through more squre on...
Regards
Iain
I have got as far as you on the thinking side but haven’t tried fitting anything yet just been out with the tape measure.
Aesthetically, taking the whole headlight apart and using the bits thus keeping the existing lines is I feel the best route though there are a lot of problems to be overcome and it is a pity that the fiat lights weren’t squarer. I did consider having some form of sidelight to take up the front corner space but the result might still end in ridicule on any trip to BBWF or anywhere else really.
I am/was intending to keep the lights in the main part of the body just sawing of the unwanted bits as the lights are mounted already.
My ride height is such that the 500mm minimum is very feasible but I would still cut a hole in the rear bulkhead for adjustment access. Using the bulkhead and under bonnet space will keep the lights below the body line but gives problems with the bonnet, though I will have to be buying fibreglass for general repair anyway.
The alternative if the lights are further forward is to have the polycarbonate raised above the bodyline (In a wedge shape!!).
One alternative, available from NF Auto for about £160 plus fittings, is the 90mm projector lights which aren't so deep.
I have to persevere with this as wiring needs changing so the effort is there anyway.
Aesthetically, taking the whole headlight apart and using the bits thus keeping the existing lines is I feel the best route though there are a lot of problems to be overcome and it is a pity that the fiat lights weren’t squarer. I did consider having some form of sidelight to take up the front corner space but the result might still end in ridicule on any trip to BBWF or anywhere else really.
I am/was intending to keep the lights in the main part of the body just sawing of the unwanted bits as the lights are mounted already.
My ride height is such that the 500mm minimum is very feasible but I would still cut a hole in the rear bulkhead for adjustment access. Using the bulkhead and under bonnet space will keep the lights below the body line but gives problems with the bonnet, though I will have to be buying fibreglass for general repair anyway.
The alternative if the lights are further forward is to have the polycarbonate raised above the bodyline (In a wedge shape!!).
One alternative, available from NF Auto for about £160 plus fittings, is the 90mm projector lights which aren't so deep.
I have to persevere with this as wiring needs changing so the effort is there anyway.
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