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Early headlight bucket assembly made easy.
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duginabug
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PostPosted: Wed Aug 12, 2009 9:09 pm    Post subject: Early headlight bucket assembly made easy. Reply with quote

Well I disassembled my headlight assemblies, cleaned what needed to be cleaned, painted what needed painting, and replaced what needed to be replaced. As I reassembled them I took some photos, and thought I’d provide a step-by-step reassembly process for those who might need help. I’m sure there are several ways to do this, and probably even better ways, but this is what worked for me and I have to say, their quite easy to put together. I’m not too sure about the correct terminology for each part, but I’m sure you’ll get the idea. So…here we go.

First I must stress safety. SAFETY GLASSES to be more specific. I had one of those little retaining springs shoot out while trying to put it in and all I felt was my hair move as it whizzed past my head. Then it ricochet off the ceiling and I lost track of it. Damn thing bout chased me out the shop before it came to rest. I did have my birth control goggles on though.

While we're on the subject of those little retaining springs: There are many opinions about what shape, how many, where they go, etc. etc. The ones you see in these photos are from WW. They are all the same and I use seven per side. Seems to work just fine. If you have different springs by all means use them. The principle is still the same.

These are the parts you will need.
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In another post, 62donb mentions putting the assembly in your lap for this next step. VERY good idea. Works quite well.
http://www.thesamba.com/vw/forum/viewtopic.php?t=237449&highlight=headlight+assembly
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Hope this helps someone. Good luck.
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vdubtt
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PostPosted: Wed Aug 12, 2009 10:38 pm    Post subject: Reply with quote

where were you a week ago! haha amazing post thanks defff should be a stickyyyyyy!
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vdubtt
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PostPosted: Wed Aug 12, 2009 10:45 pm    Post subject: Reply with quote

duginabug makes a good point.... i want to say this to all you dubbers out there. wear thoes damn saftey glasses

i have about 10 pairs and throw when they get scratched i just toss them.

Im going to be a technology teacher and my stupidity has landed me in the hospital MANY TIMES

watch out for aluminum because they cant pull it out of your eye with a magnet... trust me.....


not only saftey glasses but wear a welding helmet!! and gear!

wearing a white tee shirt and welding is not good. i burned my eyes because the reflection of welding shot under the helmet.
i woke up and i couldnt open my eyes because they had completley crusted over!
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TailTip
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PostPosted: Wed Aug 12, 2009 10:58 pm    Post subject: Reply with quote

Good post.
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Gary
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PostPosted: Thu Aug 13, 2009 8:47 am    Post subject: Reply with quote

Is there a source for the retaining spring? They look exactly like the springs that hold the glass for a set of foglights I have, and I lost one. Otherwise, this is a fantastic write-up.

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duginabug
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PostPosted: Thu Aug 13, 2009 8:51 am    Post subject: Reply with quote

Icy wrote:
Is there a source for the retaining spring? They look exactly like the springs that hold the glass for a set of foglights I have, and I lost one. Otherwise, this is a fantastic write-up.


This is where i got mine.

http://wolfsburgwest.com/cart/DetailsList.cfm?ID=111941125
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PostPosted: Thu Aug 13, 2009 9:15 pm    Post subject: Reply with quote

Great write-up, I know first hand how dangerous these little retaining springs can be, lots of tension!
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Scott65Beetle
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PostPosted: Wed Nov 11, 2009 2:25 pm    Post subject: Reply with quote

Thanks to your pics and explanation this was a snap. Hats off to duginabug
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Culito
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PostPosted: Wed Nov 11, 2009 5:57 pm    Post subject: Reply with quote

I just re-assembled mine, but it is a different style (has the adjusters in the 2 and 8 o'clock positions). Same basic method, though...
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duginabug
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PostPosted: Thu Nov 12, 2009 1:47 am    Post subject: Reply with quote

Great! I'm glad to see somebody found it useful.
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Sid Vicious
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PostPosted: Thu Nov 12, 2009 4:14 am    Post subject: Reply with quote

Great write up. The trouble I had with my new assemblies was the damned seal. It would NOT stay in place... The springs were fun, but I only had one or two go sproinging off and get lost Laughing
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Kafer66
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PostPosted: Sun Jan 03, 2010 1:04 pm    Post subject: Reply with quote

Mine are missing the tension springs on the adjusters. Where can i get them? Im not finding them at WW.
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BWD
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PostPosted: Sun Jan 03, 2010 1:10 pm    Post subject: Reply with quote

Kafer66 wrote:
Mine are missing the tension springs on the adjusters. Where can i get them? Im not finding them at WW.


Look again!
http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=111941125
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Kafer66
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PostPosted: Sun Jan 03, 2010 1:19 pm    Post subject: Reply with quote

This is the one im missing, on both sides. I cant adjust my lights.

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Kafer66
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PostPosted: Sun Jan 03, 2010 9:40 pm    Post subject: Reply with quote

The ad says 62 and back, but they sure do look like they might work. Should a 66 have these on the adjuster tab?

http://www.thesamba.com/vw/classifieds/detail.php?id=850150
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BWD
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PostPosted: Sun Jan 03, 2010 9:43 pm    Post subject: Reply with quote

I'd get them if I were you, they look the same to me!
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Ketterer
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PostPosted: Sun Jan 03, 2010 10:14 pm    Post subject: Reply with quote

Thanks for this thread. I pieced together my headlights with parts from swap meets so I've never really seen a complete set. Till now I had no idea how to install the lens seal. I guess I'm missing the headlight assembly gaskets too.
http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=111941191
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old_n_slo
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PostPosted: Mon Jan 04, 2010 9:23 pm    Post subject: Reply with quote

Very nice writeup! I'm doing mine right now and am in the middle of the paint process.

Don't forget the rubber drain tube in the fender bucket.

Jeff
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PostPosted: Thu Jan 07, 2010 11:43 pm    Post subject: what color do i paint my 63 headlight buckets Reply with quote

im restoring my 63 headlights and no one around me can tell me what color to paint the inside of the bucket
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PostPosted: Fri Jan 08, 2010 10:11 am    Post subject: Reply with quote

Found this:
http://www.thesamba.com/vw/forum/viewtopic.php?t=119187
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