(Headlight Attachment) To the Porsche engineer who. . .

Tom '74 911 · 08-26-2009, 06:48 PM

Official letter to: The Porsche Engineer Who Designed How The Headlights Attach To The Fenders:

I need your mailing address so I can send you a scathing letter and a bill for my countless hours of frustration and mental suffering. What were you thinking? Every time I take my headlights off (H4) to replace the bulbs, a cracked lens or split seal I curse your name!

I dread this job and am currently fighting this battle while replacing a cracked lens and putting in brighter bulbs. I have posted on this topic a few times before but need to vent as I have had 5 sessions in the garage his afternoon and evening bending the top flange, bending the bottom flange, stripping the bottom bolt threads, drilling and tapping the hole for a bigger bolt, using lube on the (to fat!!) seal, trimming said seal to try to make it fit better - and still, the f'ing headlight will not stay put.

I have dropped my engine a bunch of times, rebuilt the suspension, brakes, interior, and on and on. . . and I can't put the f'ing headlights back on my car.

I want that guy's name and address so I can give him some feedback. I promise not to yell - really.

Thanks for listening.

jtfreels · 08-26-2009, 07:21 PM

Oh yes no solution to offer but I struggled with this last weekend. Strangely enough it was just one side, took forever to get the top hooked on and the screw tight enough but not too tight.

pete3799 · pete3799's Garage

You're too late.......I killed him

dentist90 · dentist90's Garage

You need the special Porsche tool ...P1SS0ff.

Isn't that screw within a screw retainer just priceless. Grrrr.

4sd911 · 08-26-2009, 10:54 PM

Do keep in mind if the seal is to fat it is probably aftermarket. Must use a factory seal for this.

carrera turbo · 08-26-2009, 11:44 PM

I have a set of H1s on a carrera that i cant get off the car without the fear of damaging the paint prying on them, the screw is no problem.
Oh yea can you tell me where you buried him so i can PEE on his grave.

ed

tvanbroekhoven · 08-27-2009, 01:33 AM

Had the same problem. Fixed it by modifying one of these

and glueing it to the lips on which the lamp rests so it has better `grip`.

sc_rufctr · 08-27-2009, 02:36 AM

Ah the joy of replacing headlight bulbs.

My right one has been burnt out for about 12 months and I keep finding reasons not to change it...

Tom '74 911 · 08-27-2009, 07:50 AM

Quote:

Originally Posted by pete3799

You're too late.......I killed him

Thanks for the responses - this one made me laugh. I am in a little better humor after a night of sleep and time away - Although I didn't get to drive my P-car to work today because the headlight still isn't attached. I didn't want to even look at it this morning, just dangling there in the garage. I gave it the finger as I walked by and got into the Subaru (that'll teach it!).

My newest thought is to rivet on a new, slightly taller top flange; similar to what I've seen people do when using fiberglass fenders. I'd like to fix this problem once and for all so when I have to pop these suckers off for what ever reason in the future, it's a joy to put them back on instead of the task from he!!. If I am successful, I will post back with my solution. If not, you will continue to hear my anguished cries of frustration echo through the night!

gtc · gtc's Garage

The solution I found for the bottom threads stripping out is to use a rivet nut. You will need to ream out the hole to the appropriate size, but the rivets will provide about twice the thread depth of the original threaded tab. It is easier to get the headlight screws started now, and I no longer worry about over tightening the screw. I could take photos if it would help.

gtc · gtc's Garage

Quote:

Originally Posted by rllevin

"rivet nut"=pop rivet?

I received this notification by email, but it doesn't appear in this thread so I'll clarify just in case there was a forum error.

I used an open-end knurled rivet nut. They look like this:

I recall the thread size being M5 x .8, but I could be wrong about that, so be sure to check for yourself.

berettafan · 09-21-2009, 08:06 AM

i share your frustration.

actually attempted to swap out my sugar scoops at lunch one day secret mission style (no woman would ever understand the cost of these things) and couldn't believe how difficult it was.

Tim K · 09-21-2009, 08:34 AM

FYI,

If someone is thinking about using the rivet nuts, they can be installed without the dedicated tools. Just use a bolt with the appropriate thread for 'rivnut' and an oversized nut (nut threads minor diameter > bolts threads major diameter).

-Insert rivnut into appropriately sized hole
-Thread bolt (with nut inserted) until bottomed
-Hold nut (i.e. with a wrench), and crank the bolt until rivnut clamps onto the material (don't over-tighten)

It may help to install a star washer or something similar between the nut and the rivnut to prevent the rivnut from turning relative to the bolt while tightening. The pneumatic tool has 'teeth' that bite into the head of the rivnut to prevent it from turning. There is also a hand operated tool that looks similar to a pop rivet tool.

Tim K

KTL · 09-21-2009, 09:08 AM

Thanks for the info on the rivnut. My threads in the headlight bucket tab are just about fully stripped-out.

Also FYI the Porsche people finally got wise and changed the way the lights are mounted in '87. The H5 housing is screwed into the bucket with four tabs around the inside of the bucket. But the trim ring still uses that dreaded lower tab....... I just wait for the day when I hit a bump at the track and my Euro H4 lights go flying because the inner trim ring just popped off the ridge on the top of the bucket.....

RWebb · RWebb's Garage

Excellence Was Expected...

but not always achieved.

- you can use a fat cable tie or some nylon cord to secure the headlight with its own little safety harness

porschenut · 09-21-2009, 10:07 AM

just weld a regular nut on the back of the tab. That's what somebody did with one of the fenders I used to backdate my car. Of course, that won't help keep the top from unhooking itself.

t951 · t951's Garage

I have not had to deal with this yet. However, one of my headlamps is askew. Can some one post pictures of the modification so that I can better visualize this.

This may help in the future, not to mention be great for the pool of knowledge.

Thanks,
t.

CBRacerX · CBRacerX's Garage

Nothing like holding your breath each time you hit a rough patch of road...

80-911SC · 80-911SC's Garage

one word H-5

relay kit and good quality bulbs , not the fleabay crap

EarlySport · 09-21-2009, 07:03 PM

Quote:

Originally Posted by CBRacerX

Nothing like holding your breath each time you hit a rough patch of road...

I was on my way out of town one night to a track event, and the guy in the lane next to me points at me and at the fender as he drives by. Moments before I'd pounded my way over a steel plate on the highway put in my place by a construction crew to cover a hole or something. ( monoballs, big TB's, poly bushes, race tires = major pounding over that plate ).

I pulled over to find the headlight hanging by the wires and pointing at the ground! The trim ring was still in place - somehow!

I now tape the top and sides of the headlight whenever I'm on track, and have even resorted to using small pieces of clear tape the rest of the time.

I do have fibreglass fenders, but they have a pretty good lip. I'd love some way of screwing the headlight in from the rear ( inside the guard ) with a long screw. Maybe a bracket attached to the headlight that lines up with a hole in the bucket for a screw...