7 inch budget lucas-style round headlights

[CJH]

However.....where will you attach the cable ties? They look smooth to me.

Ah yes, good point - the lugs do look solid I agree. I had a mental picture of the open lugs, but that must have been from the advert that you linked to.

CovKid or CJH can you tell me please, do early headlights with the bigger lamp base have this adjuster ring?

I'll take a look in the morning and let you know.

[itchyfeet]

Lugs are loops on the euro car parts ones I got, here is a clearer picture and edited above also to make it clear.

Those plastic ones will need clips as said

It's also occured to me the welds on these loops may or may not be strong enough to last with cable ties especially after corrosion has set in so I'm going to look at a bracket/clip solution also, it's your choice.

P1020474 by Paul_Barr, on Flickr

[itchyfeet]

Clip/Bracket solution for dummies...

I came to the conclusion that while they are all 7 inch they all have slightly different profiles so a standard clip is never going to fit all, you need to make them.

Raw material is a large jubilee clip, it's 12mm wide and 1mm thick, this is a plated steel one if you want to be posh get stainless steel ones, if you want to be posher still then just use the flat part without the screw thread pressed into it

trim the end flat with tin snips and drill a 4.5mm hole

P1020483 by Paul_Barr, on Flickr

put a bend close to the hole, it wants to be less than 90 degrees, (you can bend it in to the right angle once fitted) then screw it in place and mark the height for the next bend

P1020486 by Paul_Barr, on Flickr

add another bend then trim off

P1020487 by Paul_Barr, on Flickr

P1020488 by Paul_Barr, on Flickr

some chamfers on the corners neaten it up, the finished clip/bracket looks like this which is probably why it has been described as a Z bracket

P1020489 by Paul_Barr, on Flickr

job done

P1020490 by Paul_Barr, on Flickr

not fitted in my van yet as I don't have the second headlight adjuster so no fitted pics yet.

[California Dreamin]

Spot on mate but if I'm being honest with you, I think that the metal strip of a jubilee clip is too soft and would easily bend releasing the lamp unit.

12mm Steel flat bar would be much better...you wouldn't need much.

http://www.ebay.co.uk/itm/Stainless-Fla ... 5d3bc38bf5" onclick="window.open(this.href);return false;

Martin

[CJH]

CovKid or CJH can you tell me please, do early headlights with the bigger lamp base have this adjuster ring?

Both of my headlights have the separate adjuster ring. Mine's an '83 van, but how can I tell if I still have the early headlights with the bigger lamp base - is there a measurement I can take? Mine look the same as your one.

Thanks for the jubilee clip idea and write up. The outer edge of the 'angel eyes' lamp that I linked to above doesn't seem so well-defined as yours, so as you say, each different lamp will require a different clip shape. I wonder if a little bit of sealant, silicon or similar, on the lugs would be strong enough as a semi-permanent solution.

[itchyfeet]

Thanis for checking

how can I tell if I still have the early headlights with the bigger lamp base - is there a measurement I can take? Mine look the same as your one.

headlamp bulb opening is much larger and the bulb is a different type, it won't have H4 moulded into the glass.

I wonder if a little bit of sealant, silicon or similar, on the lugs would be strong enough

Not in my opinion.

[Oldiebut goodie]

Spot on mate but if I'm being honest with you, I think that the metal strip of a jubilee clip is too soft and would easily bend releasing the lamp unit.

12mm Steel flat bar would be much better...you wouldn't need much.

http://www.ebay.co.uk/itm/Stainless-Fla ... 5d3bc38bf5" onclick="window.open(this.href);return false;

Martin

I agree that it is too soft,
also when I made mine up I made the length short so that the tang with the hole sits at an angle and provides positive pressure rather than just sitting at the exact distance.

[CJH]

headlamp bulb opening is much larger and the bulb is a different type, it won't have H4 moulded into the glass.

Ok - mine are all back together again now, but there's no sign of H4 in the glass.

[itchyfeet]

1mm thick 12mm wide steel is surprising strong.
There is a risk the adjuster ring tab will bend, it is much thinner than the jubilee clip so it would bend first but as far as I can see anything you screw to the adjuster ring that is not a complete circle could be bent out of the way as that tab on the adjuster ring is weak.

I can't see have 12mm thick bar could be used or even fit in the narrow gap between the headlight and grill, can you explain please?

OBG how about putting a pic up of what you have done?

[scottbott]

not to hijack this thread but I hope to converting to a south a african headlight grill,can I buy new headlight "bucket/mounts" for round lights?or is it second hand ones only?,also I have been looking at Demon tweeks latest catalogue for round headlights and they sell cibies and hella types is there much difference between the two that can actually be seen with the naked eye?

[itchyfeet]

headlamp bulb opening is much larger and the bulb is a different type, it won't have H4 moulded into the glass.

Ok - mine are all back together again now, but there's no sign of H4 in the glass.

old and new lamp bases...

[Oldiebut goodie]

I can't see have 12mm thick bar could be used or even fit in the narrow gap between the headlight and grill, can you explain please?

OBG how about putting a pic up of what you have done?

12mm thick!!!!!!! - wide methinks. (12mm x 3mm.)

I have done just the same as you but with thicker stainless, I can't remember if it was 1.5mm or 2mm - it is certainly a stiffer material to Jubilee clip metal. I have made the length shorter than yours so that the piece with a hole sits at an angle and applies positive pressure to the glass upon tightening the screw. (you need a larger hole than the screw size or elongate the hole)
(I am having trouble just sitting in a chair at present and can hardly make a cuppa let alone fiddle with vans!)

3mm would be too thick for this - you would just crack the glass or distort the metalwork behind I imagine.

[California Dreamin]

I was looking for something thinner ...but with difficulty...hence the 3mm but I found this:

http://www.diy.com/departments/steel-pa ... 23125647:s" onclick="window.open(this.href);return false;

1 metre lengths but you could make say 20 clips and sell them on her for £3 a set lol ..get your money back and then some.

Martin

[itchyfeet]

I dont know how much sheetmetal work you have done but you would never bend 3mm thick material to make this clip.
2mm may just be possible but I suspect it would be too thick also.
The part you are fixing it to is actually 1mm ( just measured it) so In my opinion there is no need to make them thicker.

I have made some more with slightly longer bends and fitted it up, I have had a go trying to move the headlight and I can't ( remember the lugs stop it moving so there is no force bending the brackets), I then used a spring balance to see how much force is needed to move them, at 8kg it sprung out enough to clear ( the lights weigh 0.5kg) it seemed to just spring and not bend, it was the screw that gave way somehow, once retightened it fitted fine so no permanent bending happened.

So I am happy it's strong enough.

P1020491 by Paul_Barr, on Flickr

P1020493 by Paul_Barr, on Flickrrl]

P1020494 by Paul_Barr, on Flickr

Still no pic OBG?

[Oldiebut goodie]

(I am having trouble just sitting in a chair at present and can hardly make a cuppa let alone fiddle with vans!)