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The new headlights from MK1 arrived – very nice – and they fitted within the steel bowls, so I started the process of putting them in place. Firstly I replaced the plastic raw plugs with the proper “nylon nuts”, and wired in H4 lamp connectors. I’ve used H4 for all 4 lamps, wiring the outers to dip and the inners to main beam. Many use H1 as the inners, but I perfer to use the same bulb type throughout – less spares to worry about.
You can see from this picture (courtesy of Rimmer Bros) how the lamps fit together. I would have saved a lot of time, had I looked at this first.
The light units are sandwiched between the outer chrome ring and the inner steel ring, with adjustment being provided by moving the inner steel ring via the aduster screws. I made the mistake of assuming that the light units fitted between the inner ring and the steel bowl. I wondered why the light units didn’t quite fit, and thought that it was just because the new lamps were pattern parts. The inner rings clamped the light units tightly enough but they wouldn’t fit flush with the front of the ring so adjustment was really difficult and not accurate enough for an MOT.
As I wasn’t happy with the fit, I took them off again and checked the manual. Fitting them the second time, and in the correct way led to much better results. Just as I had hoped. I’ll adjust them again on one dark night this week. Then I can put the grill back on.