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Author Topic: Headlight adjusters  (Read 1674 times)

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cignet

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Headlight adjusters
« on: 05 June 2022, 19:08:36 »

What are the current options on replacing broken adjusters please? MOT failure threatens!!
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Nick W

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Re: Headlight adjusters
« Reply #1 on: 10 June 2022, 22:19:27 »

Here's a basic 3D model taken from an undamaged adjuster:





Making one like that isn't worth the time unless you have a spare CNC and the market for a couple of hundred of the things. That market is long gone, as is the supplier who made the aluminium ones. There are some cast resin ones with an inserted ball that come up on Ebay occasionally, which just about work.


I'll happily send you the model, and a PDF of the dimensions, which will allow you to make something like this:





there are several ways that could be done, using basic hand tools and readily available materials.
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cam.in.head

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Re: Headlight adjusters
« Reply #2 on: 11 June 2022, 10:07:32 »

totally agree nick.
yes the originals are that shape but obviously dont have to be. the one above works perfectly fine and i made mine to a similar style using just a flat plate,welded on nut and welded on ball end. the advantage of this is also that you can fit it without having to dismantle the headlight( lense off ) .yes its fiddly to get in but can be done.
and theoretically should last forever !
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cignet

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Re: Headlight adjusters
« Reply #3 on: 11 June 2022, 19:09:21 »

Many thanks your offer of help will gratefully accept!
Have just spent many hours trying to get a workable unit from 2 scrappers!!!!
Pl advise how to proceed
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Nick W

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Re: Headlight adjusters
« Reply #4 on: 11 June 2022, 20:54:47 »

Many thanks your offer of help will gratefully accept!
Have just spent many hours trying to get a workable unit from 2 scrappers!!!!
Pl advise how to proceed


Get some 3mm thick steel plate, big enough to make the bases. Cut to size, and file the edges so they slide in the lamps
Get some 8 or 10mm thick steel for the upstands.
Drill them M5, but bear in mind their centre heights are different. File to fit.
Weld all 3 pieces together like the picture.
Solder a (I think) 6mm ball bearing onto a short length of M5 studding

Assemble into the lamps.

This is a hacksaw and file job that might take an hour if you don't have more powerful tools.

As you have at least one glueable adjuster, use that for the dimensions.

The only used units worth buying are ones you can inspect for aluminium adjusters, and that the adjuster screws actually work. If they don't have both, don't buy them. Good luck finding any!
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cignet

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Re: Headlight adjusters
« Reply #5 on: 12 June 2022, 18:46:01 »

Many thanks your data. Will certainly try this minimalist piece of engineering!!! Altho i find oven heating very effective i will certainly try fiddling next time!!!!
I had not realised the two axes were different or that a ball bearing could be used.{think 6mm is too big but easy checked before making}
Thanks again guys very much appreciated. 
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Nick W

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Re: Headlight adjusters
« Reply #6 on: 12 June 2022, 20:44:29 »

Removing the lens allows you to clean inside it, lubricate the bits you can't get to normally and ensure everything works as designed. I reckon on spending about 30minutes per lamp, which includes polishing the outside.


I tried a couple of methods for removing the lens, but using the oven was quickest, easiest and less likely to damage anything.
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MonzaGSE

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Re: Headlight adjusters
« Reply #7 on: 13 June 2022, 17:50:41 »

I have found the adjusters from tyc/depo aftermarket lights to be promising. The aftermarket lamps themselves are in my opinion useless/extremely low quality. But the adjusters inside them seems far superior to the original hella adjusters. Different design but fit in the hella lamp. I have picked up a couple of broken/damaged depo lights over the years. Always tear them apart, remove the adjusters and bin the rest. I have also bought a roll of butyl band from eBay. Usually add a little extra butyl to the headlights before i seal them up again to be sure to avoid leakage.
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