Installing new headlight seals and proper fitting

Sonic dB · Sonic dB's Garage

My 86 is equipped with H4s. The headlight seals were both ripped so I purchased new ones from Pelican to replace them with.

The way the headlights fit on (top groove and bottom screw) is a pain in the ass to get to fit right. What Ive ended up with are tiny gaps on the sides of my head lights between the headlight rim and the new rubber seals...

In other words, the headlights are on tight, but not flush with the rubber seal all the way around. Is this considered to be "normal"? Is there a better way to do this so it is all flush and looking perfect?

Bob's Flat-Six · Bob's Flat-Six's Garage

Maybe the rubber gasket isn't seated in the fenders all the way ? They can be a bit of a hassel as I recall.

jriera · 05-16-2003, 07:24 PM

Sonic db, my experience is that if you soak then in water and soap first will be a lot easier to put them properly.

Also be aware that it is very easy to break them by the seam... don't ask me how do I know...

After some 'good soul' crunch my passenger side fender (and the H4 glass) I did replace the glass, ring and gasket and yes, it is a pain to put properly, but with patience (and soapy water) will be installed properly.

Hope this helps.

stealthn · 05-16-2003, 07:35 PM

Sonic.

It took me like an hour each to get them on, I would have to take breaks from gettign so frustrated. The trick was put the cover on a little on an angle then rotate into place.
Jordi, I don't know if I'd want wet rubber pressure fit between two pieces of metal? These buckets rust fast enough as it is....

Sonic dB · Sonic dB's Garage

I didnt have any trouble putting the seals on...just held the top with one hand and moved it around with the other. However, when putting the headlight into place it snaps at the top (barely) and then tightens up when I tighten the bottom screw.

The is less of a gap between ring and seal, at the bottom and the top then there are on the sides of the lights.

Its not a huge problem, but its not 100% new looking either. Maybe Ill try the method of angle and twist that Bob recommends above.

toolman · toolman's Garage

I got mine on by hooking the top first, then checking to see if the hole lines up with the screw hole, then pressing from the top around one side and pushing the ring toward the other side to get the last retainer locked in. Its like mounting a tire on a rim.