Headlight bucket rust.
 

How hard is it to replace a headlight bucket? Can it be done without painting the fenders? I finally replaced my lights with the euro H4's and made the grizzly discovery of rust in the right bucket. It seems the PO never installed seals when working on the lights. Piss me off. There is two small holes so the rust has perforated. Any thoughts would be great. Also there was so much paint on the rim of the buckets I couldn't get the new lights to fit without chipping it away and sanding down to the original silver color. I plan a re-paint in the distant future so that part didn't bother me so much. The new lights look great though.

Well...maybe....you can clean out the bucket and repaint and / or use POR-15.

Even if you have a few perforations...remember..the racers on this board purposely swiss-cheese ( drill) the bucket and remove the headlight to get more air to the front oil cooler. A "fix" as I suggest, even with a few pinholes...won't hurt ya...

When you're done..make sure the bucket has a big ( 3/8" or so) drain hole on the bottom surface. Make sure the rubber headlight trim seal is back in-place too.

Wil

I was thinking along those lines. I am not sure I can buy Por 15 in Canada. I've looked for it but haven't found it yet. Do any of the other Canadian Pelicans know if it's available up here.

see here---> http://www.por15.com/

look at "international orders"...and follow their advice....

- Wil

I ordered mine at www.http://www.canada-por15.com/. Arrived next day to Markham with no problems...