Headlight Bucket Color

[JohnP_02]

Larry and Steve, how in the heck did you get that little ovoid retainers off?! I am having little or no success or maybe just being too careful. Everything else is apart and ready to go. 

[Conserv]

17 hours ago, JohnP_02 said:

Larry and Steve, how in the heck did you get that little ovoid retainers off?! I am having little or no success or maybe just being too careful. Everything else is apart and ready to go. 

Yes,

 

It was a bit of a pain, John. (I’m guessing you’re talking about the small metal retainers that act like nuts, and not the plastic retainers.) I held the ovoid retainers with a pliers and unscrewed the bolts from them. The pliers did minor damage to some of the retainers, but that largely disappeared with the re-plating — I might have touched up the worst damage with a small file, before the re-plating. After the buckets are re-assembled, you won’t be able to see anything but glowing zinc!

 

Best regards,

 

Steve

 

[2002#3]

John,

I saw your question.  My original post was 6 years ago so for the life of me I cannot recall your referenced "little ovoid retainer".  My bad.  I do recall working with all those small bits being a really serious PIA.  Please post a photo of that little sucker to refresh my memory.

Thanks.

Larry

[JohnP_02]

9 hours ago, 2002#3 said:

Please post a photo of that little sucker to refresh my memory.

Sorry about that Larry, I thought I had commented on Steve's other thread with the pictures. I tried for a bit over the weekend, but gave up after not making any progress. Its annoying as the rest of the buckets are disassembled and ready to be shipped out for plaiting along with a bag of other stuff. Anyway, its this little wanker retainer ring below:

 

 

[2002#3]

John,

 

I have no idea how I removed, cleaned, and reinstalled those funky little retainers.  However, here is documentation (photos) I did so.  However I accomplished this extraordinary feat, I did it without damaging any of the other delicate parts.  Hmmm...forgot I ever did it.  The end result (with power coated buckets) was acceptable.

 

Larry

 

 

Edited December 6, 2023 by 2002#3

[Lucky 7]

The headlight adjusters were probably fine when new, but after 45 years I found them a bit wanting. They suck to take apart and the plastic nuts are easy to break.  McMaster-Carr to the rescue:
 

5125K39

Brass Knob with M5 x 0.8mm Threaded Hole, 19mm Head Diameter

94185A584
Super-Corrosion-Resistant 316 Stainless Steel 1 Threaded Rod, M5 x 0.8 mm Thread Size, 300 mm Long

 

98691A115
General Purpose Brass Washer for M5 Screw Size, 5.300 mm ID, 9.000 mm OD

 

94205A240
316 Stainless Steel Nylon-Insert Locknut, M5 x 0.8 mm Thread, DIN 985, Packs of 50 Pack

 

8975K584
Multipurpose 6061 Aluminum, 3/16" Thick x 1/2" Wide, 1 Foot Long 

 

1920N36
Mil. Spec. Extension Spring with Loop Ends, 1.5" Long, 0.360" OD, 0.055" Wire Diameter, 

 

 

With a few standard M5 nuts, all of it makes this:

 

 

The aluminum bar gets cuts down to match the original plastic nut dims, then drilled and tapped for M5 thread. The threaded rod gets cut into 4 pieces and a die run over the cut ends. The springs are full loop, so I trimmed the loop back to make them into hook-end per OEM. Other than that little bit of fabrication it’s all easy assembly. Closer look at the stack order:

 

 

The locknut is upside down so the acorn side matches the concave area on the bucket. So locknut goes down the rod from the knob side, then that assembly pushes up through the adjuster slot on the bucket, then the washer, nut and finally the knob go on. Adjust it all snug and lock the knob/nut together.  Then you can install the bucket into the housing and thread into your new aluminum nuts. Easy enough:

 

 

Now I can adjust all day long without worrying about broken plastic bits. And if knurled brass doesn’t steam up your jeans, there’s no hope for you. 
 

[JohnP_02]

@Lucky 7 that is fantastic! At least I will have everything I need if I wind up breaking stuff taking the adjusters out. Thanks!

 

John

[jp5Touring]

Love the brass knobs  I used Ireland Engineering kit a year ago with good luck.

 

https://www.iemotorsport.com/product/headlight-bucket-hardware-kit-2002/

[3PinFever]

How did you get the IE T nut to fit/hold in the bucket?  I almost want to reuse the old plastic rectangular nuts. 

[JohnP_02]

Could use a little help with identifying the correct specs for the circled long adjuster screw and those two concave washers. Realoem does not have them listed for some reason. Thanks!

 

Edited January 21 by JohnP_02