Gumball
03-28-2013, 11:32 PM
I'm just about at the end of sub-assemblies that need to be put together and test fitted to the body. Today I put together the head lamp assemblies using some Lucas PL700 housings with H4 bulbs.
I finally understood what everybody is complaining about with the three stamped tab that are supposed to hold the bulbs to the adjuster ring when I just put a little pressure on the glass face when the adjuster ring was installed in the bucket and could see the tabs bend. Sure enough, it was just enough to make the bulb housing loose and cause it to rattle. I took the tabs off and made some reinforcement tabs to use with the originals (because the originals have "teeth" that hold the bulb housing secure). These were made from some scrap .060 aluminum that I had laying around. Just held the reinforcements in place over the original tab, marked them, drilled them, and used the FFR supplied self-tapping screws to thread them. Holding them over the original tabs enabled me to get a good bite and they provided more than enough extra rigidity to keep the bulb housings tight.
http://i845.photobucket.com/albums/ab15/CCRsAC/StiffeningTabs_zps3cb0fb6b.jpg
And a couple of pics of the head lamps:
http://i845.photobucket.com/albums/ab15/CCRsAC/Headlight_zps4b4a81c6.jpg
http://i845.photobucket.com/albums/ab15/CCRsAC/FrontEndwithHeadlampsTestFit_zps3f1346b1.jpg
I finally understood what everybody is complaining about with the three stamped tab that are supposed to hold the bulbs to the adjuster ring when I just put a little pressure on the glass face when the adjuster ring was installed in the bucket and could see the tabs bend. Sure enough, it was just enough to make the bulb housing loose and cause it to rattle. I took the tabs off and made some reinforcement tabs to use with the originals (because the originals have "teeth" that hold the bulb housing secure). These were made from some scrap .060 aluminum that I had laying around. Just held the reinforcements in place over the original tab, marked them, drilled them, and used the FFR supplied self-tapping screws to thread them. Holding them over the original tabs enabled me to get a good bite and they provided more than enough extra rigidity to keep the bulb housings tight.
http://i845.photobucket.com/albums/ab15/CCRsAC/StiffeningTabs_zps3cb0fb6b.jpg
And a couple of pics of the head lamps:
http://i845.photobucket.com/albums/ab15/CCRsAC/Headlight_zps4b4a81c6.jpg
http://i845.photobucket.com/albums/ab15/CCRsAC/FrontEndwithHeadlampsTestFit_zps3f1346b1.jpg