Clumsy design for Headlight front metal ring.

is it me or does anyone think that the metal ring in the front headlight is ridiculously fussy to put on....

not keyed so you have to rotate it this way and rotate it that way to get in on right.

then if you tighten the screw just a little too tight, the ring pop off, hahah, only to start all over again...

just poor design in my opinion...

as much as I love looking at and driving my SC every day of my life, rain, sleet, snow, and ice, i have to point out the frustrating things about it....like THE AIRBOX EXPLODING!



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83 sc euro cab

While I've only had H-4's off, and back on once; it was without any "ring pop-off" event. Hmmm. . .are yours H-4's or US -spec?
So you actually had an airbox explode? I had read that the newer SC's, with their manifolded cold start injectors, very rarely did the nasty pop.
Can any out there confirm this?

'81 SC

Not sure about that. I would still install a pop off valve.

Here's the convincing data:

CIS airbox: $300.00
Installation: Drop Engine, disassemble entire intake, reassemble in new airbox, Reinstall engine (8 hours labor at $60-70 per hour unless you do it yourself)

Pop off Valve: $40.00
Installation: Remove air filter, cut hole, install valve, Reinstall air filter (1/2 hour labor)

Cheap Insurance.
Enough Said.
Nick.

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_ _ __ _ _
Nick Shumaker
1982 911SC Coupe
nickshu@yahoo.com
PCA -- Rocky Mtn. Region

I agree. The design of the H-4's is crap. I'm not sure how the construction of these compares to the other H designs, but it is definitely more complicated than it needs to be. I bought my car as someone else's unfinished project(lots of assembly required) and had no experience with Porsche's(learned a lot of things the hard way). Took me forever to figure out how to assemble the bucket and trim ring with those stupid spring clips. Had a hard time getting the bottom screw to start in the bracket also. After a lot of effort expended, ended up just bending the bracket so the screw would line up. Can't believe Porsche designed a headlight assembly where the only thing holding it in is one screw and a little lip on top. As for the pop-off valve, definitely install one. My '80 was backfiring like crazy recently. Can't imagine the damage it could've done without the pop-off valve installed.

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'80 Targa

I have a pair of H5's

The headlight carrier assembly is held in place by four screws (these screws are differebt than the ones used for alignment)

the problem is, it's a tight area to get your fingers in for the screws...if you secure the 3 screws and then DROP the fourth screw inside , then you have to undo ALL three screws again, lift out the carrier asm and find the 4th screw you just dropped and start all over again until all 4 screws are secure

after the carrier asm is in place, THEN the ring goes on.

it's not bad until you get ready to slip the ring on...one screw at the bottom holds it in place....and it's a real ***** if your nut where the screw goes in is missing.


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83 sc euro cab

When I changed bulbs on my H-4's recently, I too was amazed at what a mickey mouse setup it was. I think I got the rings on tight, but it would not surprise me if they flew off after hitting a large bump in the road.


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Doug
'81 SC Coupe (aka: "Blue Bomber")
Canada West Region PCA
members.home.net/zielke/911SC.htm

Um, they do sometimes pop off if you hit a big enough bump. (Ask me how I know.)

Make sure the upper lip is in good shape, and make sure the screw and the hole are a good match.

I think this could have been added to the old thread about Porsche's design and engineering 'blind spots:'

http://www.pelicanparts.com/ultimate/Forum3/HTML/004297.html

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Jack Olsen
1973 911 T (3.6) sunroof coupe
jackolsen@mediaone.net

I haven't been around here long enough to have read that thread. Very entertaining; thanks for resurrecting it, Jack.


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Doug
'81 SC Coupe (aka: "Blue Bomber")
Canada West Region PCA
members.home.net/zielke/911SC.htm

Hello

As long you start the engine like the factory recomended it and have a good maintained engine those blow ups are nill.

Grüsse

I have no problems with my H4s. They are hard to put on but once you get the hang of it they work fine. Just like most things on a Porsche

I'll agree with you '83, it can be a bugger. Not sure how it came from the factory, but I know if you buy a new replacement from the dealer, it's made from brass (not sure if that has anything to do with it) Porsche got it right though on the 993, flip the lever and the assy is out...

I do have to admit that when I changed my headlights to the H4's on my '86 it wasn't the easiest thing to line up the retaining screws. I do think that they look a lot better than the wide rimmed sealed beam units. Has anybody noticed how much these headlights resemble the ones on old VW beetles. I think I've seen old bugs with these same headlights on 'em.

Wow - I have just come in from the garage after fiddling for ages with the damn headlamps - tho I did find something v. interesting - more on that in a sec.

The rubber seal had come loose, so I thought I'd have em off. So I take it off and things start falling on the floor! What the hell are those metal clip things for? After messing around for ages, I realised the seal was too old/knackered to work again and I just put it together again without the clips and seal temporarily.

Now to the interesting bit. I took the lamp out and inside the housing (of the fender) there was a little box stuck inside. The little box was magnetic and read 'magnetic key holder'! Turns out it has the original ignition key and a spare door key. Why would anybody do this? For a start you would need tools to get them out - really strange. The previous owner obviously wasn't aware of them being there or he would have told us when we bought it....

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'72 911E Sporto

I guess a bunch of folks out there bought the wrong car ... if you wanted a headlamp assembly that is plastic and glue construction, and a throwaway like Hondas and Tauruses (Taurii?) at Hundreds of $$$ when a rock or larger object desroys the lens! Or, you could buy the H5 lamp assemblies ... more throwaways!

The H1 and H4 lamps predate a design philosophy that most of the regulars here grew up with ... they were designed for repair, rather than replacement. Millions of VW Beetles and 356s were built prior to '67 with very similar headlamps. And, I have never heard such complaints about them being 'crap,' which, of course, is pure BS!

Maybe the following explode d diagram would help the ones who aren't too lazy!

http://www.pelicanparts.com/911/911_Parts/1974-75/9-6.JPG
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Warren Hall
1973 911S Targa

[This message has been edited by Early_S_Man (edited 04-01-2001).]

Warren, that picture is intesting but doesn't help me as to where the clips go?

Also the picture shows 2, but in my headlamp there were about 8 (I am fairly sure not all were on, but they all fell off the moment I got it free).

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'72 911E Sporto

OK ... this is one case where the Haynes manual everybody likes to mouth-off about does have pictures and a procedure for replacement of the glass lenses of both H1 and H4 headlamps!

But, to get you started ... the clips are kind of a 'mangled-L' shape, and there are two different styles, 6 upper, and 5 lower, which are less crooked. The short end is hooked under the lip of the outer ring, the bent part is pressed down against the lamp body flange, and finally, the other end is hooked under the lip of the ring. This assumes you have the rubber sealing ring, lens, and outer ring all aligned before placing the main lamp body down over the lens! It would be a good idea to use a criss-cross patern in placing the clips!
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Warren Hall
1973 911S Targa

[This message has been edited by Early_S_Man (edited 04-01-2001).]

I think if you are able to overtighten the lower securing screw, then you have the wrong screw. The original one is shouldered so that it can only be tightened to the proper depth. There are also little plastic washers on these screws that help to keep from losing the screw due to it falling out when you remove it.

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Tyson Schmidt
72 911 Cabriolet
92 C-2 Cabriolet

I took my time when installing my H-4s, but I had some trouble too. The H-4s are high quality units in my opinion, but the way that they are held on is definitely not the best that I have seen. The top lip must be in pristine condition. I installed new seals with my installation, which could have made the job a little more difficult. When I removed my old original headlights, I noticed that the previous owner must have ditched the seals...probably because he could not properly secure the headlights with them on. Nonetheless, the mounting setup has definite room for improvement! You do have to cut some slack for a car that is over 27 years old though...

Bill

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William Armentrout
1973 911T
2.7 carerra rs specs
www.geocities.com/william_armentrout

I had a 72911 and the painted ring came off and went over the windsheild and on to the road behind me!! And I put on the brakes to make a U turn and the headlight fell out and was sliding across the road bing bang boom talk about blowing your pose!! I was totaly suprized that it didn't brake just skined up the chrome ring a little The painted ring didn't fair so well I was standing on the side of the road waiting for the last car to go by some old fart in a beat up datsun pickup WHAM!! so much for that!!Oh well what next?

Sounds to me like you guys haven't discovered the greatness of Gel SuperGlue and all of its applications. My rings (the one for the H-4s) do not pop off.


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Kurt B
'84 Carrera Cab.
carrera_cabriolet@yahoo.com