Another Silly Post: Headlight Covers

[LateApex]

I think everybody who has built a coupe has wrestled the headlight covers a bit:

The fit is rough, that is to say that with the fiberglass variance, a fair amount of sanding is needed to flush mount the lens. Part of the program ...
Regardless of how well one may align the lens, road grime will creep under the lens. Cleaning suggests removing the lens whenever deep cleaning might be needed.
From a fit and finish / trim perspective, there are a variety of approaches that builders have taken. Some have painted an "eye liner" around the perimeter that serve to hide the SS angle brackets.


Has anyone come up with a thin profile bulb seal for the lenses?
If one is even periodically removing the lenses for cleaning in the headlight tub, the SS screws holding the lenses to the "L" tabs are going to fail. What have you done here?

My situation is a bit screwy, as for whatever reason, one of my lenses is 1/8" thick; the other 1/4" thick. Not sure why that occurred in my case (or should occur in anybody's case), but as you may have guessed, I took measurements off the thinner of the lenses (without checking the thickness of the matching lens - Why would one do that?) and one lens is proud. No satisfaction from FFR when brought to their attention. Yep, that is a gripe. With the angles involved in the headlight tub, a 1/4" piece of acrylic is a PITA.

Have you also dealt with issues like this, and how?
Have you a second source for Coupe lenses you recommend?

Happy 4th of July! Took the Beast out for a 100-mile run with my 21-year-old son on Summer break from college (he drives a Mustang) yesterday. Even let him get familiar. THAT is a whole different topic!!

Best ...

[michael everson]

What GEN kit do you have? Neer heard of 2 different thickness lenses. Is it truly 1/4 thick? Can't imagine Factory five wouldn't replace one so they match.
Mike

[Jeff Kleiner]

Thickness aside, before you get too carried away with fitting check them closely for air bubbles. When sun shines through them the bubbles will create shadows that look like dirt spots inside the headlight coves. Two sets that I got with Coupes were flawed but FFR replaced them.

Jeff

[LateApex]

2021 Gen 3.

Maybe this Winter, when I'm itching to work on something when the snow is flying, I'll make some molds to form some lenses :-)

[michael everson]

You need to call and talk to someone else over there.
Mike

[LateApex]

Thx Jeff. Fortunately, mine are clear. I am wrestling with a better scheme for attaching the lenses for easy removal, for a more secure attachment, and to keep the grime out of the tubs. Alternatively, I may just nix the covers and update the headlights with a modern LED variant with integrated parking lights & turn signals as others have done, but that means I need to patch the fiberglass and throw some more paint on the bonnet. Maybe after I've taken a few more rock chips on the nose ... ;-)

[Rsnake]

I tapped the brackets and use stainless button head screws to mount the covers. When it rains I do get dirt inside but it takes about 30 seconds and I can remove the covers and clean. Not difficult. I liked the clean look without any type seal.

[JimStone]

Thx Jeff. Fortunately, mine are clear. I am wrestling with a better scheme for attaching the lenses for easy removal, for a more secure attachment, and to keep the grime out of the tubs. Alternatively, I may just nix the covers and update the headlights with a modern LED variant with integrated parking lights & turn signals as others have done, but that means I need to patch the fiberglass and throw some more paint on the bonnet. Maybe after I've taken a few more rock chips on the nose ... ;-)

No offense meant to anyone who has built one of these beautiful cars, but to me the side scoops and headlight lenses have had a sort of "cheap" look to them compared to the rest of the car. I don't plan on using them. The car below has been one of my inspirations.


186752

[Jeff Kleiner]

No offense meant to anyone who has built one of these beautiful cars, but to me the side scoops and headlight lenses have had a sort of "cheap" look to them compared to the rest of the car. I don't plan on using them. The car below has been one of my inspirations.


186752

I know that car well. It has neither headlight covers or scoops (it also had the flanges removed from around the openings so there is no longer an option for using side windows).

Jeff

[LateApex]

That is what I am leaning to as well - thx!

[LateApex]

No offense meant to anyone who has built one of these beautiful cars, but to me the side scoops and headlight lenses have had a sort of "cheap" look to them compared to the rest of the car. I don't plan on using them. The car below has been one of my inspirations.


186752

I like the dark wells (or coves, or tubs)!

[LateApex]

@ Rsnake, I have used PEM Nuts in this kind of application, although the brackets are "hard" and should keep a tapped thread well. If the PEM Nut hole is exact, they hold up very well, including in air frames I have built that have a lot of vibration at supersonic speeds. Which ever case, getting onto machine screws seems to be the order of the day :-) Thanx for your comment!