Club 80-90 Forums

Much clearer on the fittings now. I was getting a bit confused what side the mounting plates go, but see how it all falls into place re the mountings.

Cruz wrote:No. because you will refit them in the same place

Cheers - clearer now (even to my mind!).

HOW TO UPGRAGE TO SQUARE HEADLIGHTS

Twin square are pretty straight forward. I did mine the other week in about 2 hours and I'm an electrical numpty. However I am a military aircraft fitter by trade and have a cheap Lidl soldering iron

I bought the correct lower mounting brackets (seen below) from VW 255-853-647 x 2
Now available again from http://www.brickwerks.co.uk/shop?page=s ... gory_id=57" onclick="window.open(this.href);return false;



Then to fit you need to gently bend back the two outer mountings on the Van with a hide mallet or something. not quite 90 degrees back should do it (that way you can bend them back if you ever go back to round headlights). They are the outer 2 of the 3 tabs that the grill is secured to, as they get in the way of the square light assemblies and you don't need them for the square grill.

Screw the VW mounting tabs onto the lower inner corners of each lamp assembly so that the are orientated as in the picture above

The two outer upper and lower screw holes on each side are used to attach the square lights. So screw the light fittings to these two holes then mark where to drill the upper inner hole and the two lower holes for the mounting tabs.

Remove light assemblies and drill holes approx 3 to 3.2mm (I used 4mm tamper proof self tappers). Be carefull not to damage your paintwork or any wiring looms as you break through.

Rivet the mounting tabs to the body. Again watch the paintwork.

I am assuming you got the wiring looms with the headlights?

Leave your existing side light wires alone you can use these

Snip off your existing headlight connectors about 3 inches back from the plastic connector block

Now solder and heat-shrink the wiring looms you got with the square headlights to your existing loom matching up the wire colours on each side. Ignore the side light block on the loom. Tie wrap this up neatly out of the way and maybe tape up the socket to prevent any water getting in.

Fit headlights to body remembering to plug them in first.

Fit square grill

Ring local MOT place to get the lights re-aligned

Stand back and admire.


As promised here's some pictures

Cheers these are super. Really shows me what to do now. Gonna attempt it upon the next decent day.

You said you used 4mm tamperproof screw. Though if a bulb goes, you have to take off the frame don't you to renew?

Once complete I'll post up some pics.

I used tamperpoof security screws, but obviously they are not tamperproof for me

what I thought!

Do you know the length of them what you used was it 25mm?

Yep. That was the shortest screwfix did

Cheers many thanks.