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Headlight adjusters

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cignet:
What are the current options on replacing broken adjusters please? MOT failure threatens!!

Nick W:
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.

cam.in.head:
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 !

cignet:
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

Nick W:

--- Quote from: cignet 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

--- End quote ---


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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