240 Headlamps

[geoffo]

I finally got around to making two decent refurbed headlights from the four I had in my spares dept; rust on the screws going into plastic is the big problem - any suggestions on how to prevent it? I ended up buying a new set so I have these spare - with either plastic chrome or stealth black trim - if and when your screwdriver crashes through....

[T5Ash]

I have a good second hand pair i would sell and another pair i was told are only 12months old by the previous owner.
Breaking 3 cars if anything else is needed
Ash

[Clifford Pope]

I found with the new reflectors I fitted that the replacement plastic pop-on pivot things also pop off quite easily. I fitted the nice new reflectors, sidelifhts and plastic trim, bolted into position, but when I pushed the bulb connector onto the three prongs the reflector fell off inside the unit.

The second time it did this I found it was possible to retrieve it and pull it backwards to re-engage the three pivots, but it was very fiddly.
I needed to grip the reflector firmly while fitting the plug, which is impossible with the rubber dust cover.
In the end I fitted the connector first without the rubber, then cut a slot in the rubber, fitted it and secured with a large jubilee clip.

I'm sure the old kind you had to soften in hot water were better. The seemed to regain their firmness when they cooled.

[rustytoba]

Many thanks for the tip, it may be possible to work round this by fitting the bulb connector to the bulb prior to fitting the bulb to the headlamp unit.

Some pics of the old faded reflector, new reflector and newly recon unites ready to be fitted once the front of the 240 has been cleaned up.


Rusty