Covered Headlight Conversion S1.25

Talk about the E-Type Series 1
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Robsan
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#21 Re: Covered Headlight Conversion S1.25

Post by Robsan » Wed Nov 10, 2021 5:05 pm

:yeahthat:

I agree. had my dooubts originally.......... but you have soldiered on .................. to unmarked territories. very impressed with exposing the seams. Well done that man :-)

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eddiecross
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#22 Re: Covered Headlight Conversion S1.25

Post by eddiecross » Thu Nov 11, 2021 11:52 am

Updated post- Trial fit looks pretty good. and got away without damaging the surrounding paintwork.
I want to remove them for attaching the flanges but also want to tack the bottom lip of the 2 pieces together to stop water ingress but without closing the gap up. I may slide in a strip of metal to substitute for the fixing clips.
Thanks for the support and comments. Makes it a less solitary pastime
Eddie
67 FHC

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keithmac
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#23 Re: Covered Headlight Conversion S1.25

Post by keithmac » Sat Nov 13, 2021 1:38 pm

Hi Ed,
Not sure if this of any help. Took some pics yesterday that may be of interest . ( My part time job is restoring E-Types, currently working on four ) Appears to be a tab that just presses against the sugar scoop. There is no right angle lip under it. The scoop also seems to rest on the flange of the section you just cut out for the new chrome trim. This is the right side of a a 66 OTS
Cheers,
Keith
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Early 1967 S1 OTS, 1952 MG TD

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Geoff Allam
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#24 Re: Covered Headlight Conversion S1.25

Post by Geoff Allam » Sat Nov 13, 2021 4:25 pm

That is interesting. Do you find the same tab on all 4 cars? My car had no support bracket at all but had been through a front end accident and repair. I found a rectangular paint shadow on the sugar scoop in the same location as the L bracket shown in the picture I posted earlier. (Picture sent to me by a person with an pretty original 3.8). Possibly the support mechanism changed as production went on?
Geoff Allam
67 series1 ots under restoration
64 series 1 fhc burning lots of oil
53 xk 120 fhc sitting in garage waiting for attention

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eddiecross
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#25 Re: Covered Headlight Conversion S1.25

Post by eddiecross » Sun Nov 14, 2021 8:15 pm

Updates on attaching the left side covered headlight flanges:
Mix of tacks and using the original rivet holes.
I was going to tack and then offer up the chrome surround before riveting but once the flanges were cut to fit and offered up there was pretty limited movement possible so just went for it.
I closed the gaps at the top and bottom hoping it will make them a bit more water tight. If the wing needed to come off its only 10 secs work with a cutting disc to slice them apart again.

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Dressed down the welds. Checked the marks for the holes about 4 times then drilled them
The plexi is very flexible so no dramas tightening down the screws
Trial fitted the headlight panel panel and wanted to fit the sugar scoop but timed out
I have fitted captive bolts to the panel for the sugar scoop (so I could move them around to get the best fit but I don't think there is enough clearance to slide the scoop in and clear the bolts.
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Last edited by eddiecross on Tue Nov 16, 2021 10:51 pm, edited 4 times in total.
67 FHC

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eddiecross
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#26 Re: Covered Headlight Conversion S1.25

Post by eddiecross » Sun Nov 14, 2021 8:26 pm

Thanks for the information Keith. That will come in useful for offering up the sugar scoops
I have the plexi lenses from Moncoque and looking good to fit the chrome bezels, even with the so-so repro rubber seals. The flexi fit is pretty loose as much thinner than the glass ones. I may need sealer.
Not sure if new ones would fit better as not stretched by the glass lenses.
67 FHC

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eddiecross
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#27 Re: Covered Headlight Conversion S1.25

Post by eddiecross » Fri Dec 10, 2021 11:48 pm

Offering up the headlight panel and trial fitting the sugar scoops.
Really struggling getting the scoops to fit with no gaps at the front.
The scoops have captive nuts welded on the three tabs. Just not working
I'll post images of the fixings later
All suggestions more than welcome.

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67 FHC

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Robsan
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#28 Re: Covered Headlight Conversion S1.25

Post by Robsan » Sat Dec 11, 2021 9:28 pm

I have the conversion set but havent got to fitting it on the car !! I have attempted to fit [ bolt] the sugar scoops to the headlamp diaphragms using the welded captive nuts.
On both sides only two bolts really line up, and getting the third to line up is, either really really difficult [ and not really right]. and the other side the third hole doesnt really align at all ?? A mystery in the Quality dept perhaps ???

have you just checked for three hole aliagnment from scoop to diaphragm ?

doesnt the scoop to bonnet gap have a rubber sleeve or something that allows for a bit of tolerance in that interface ??

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Geoff Allam
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#29 Re: Covered Headlight Conversion S1.25

Post by Geoff Allam » Sun Dec 12, 2021 3:29 am

This is the page from the series 1 parts catalogue pertaining to the sugar scoops. You will notice that there are distance pieces listed as well as extra nuts. The scoops require shimming to fit. Chuck has a write up somewhere about how they fit but I am unable to find it. I would suggest that you call or email him to get the correct procedure to fill in that gap. He is always very helpful that way.
Geoff Allam
67 series1 ots under restoration
64 series 1 fhc burning lots of oil
53 xk 120 fhc sitting in garage waiting for attention

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Geoff Allam
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#30 Re: Covered Headlight Conversion S1.25

Post by Geoff Allam » Sun Dec 12, 2021 3:30 am

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Geoff Allam
67 series1 ots under restoration
64 series 1 fhc burning lots of oil
53 xk 120 fhc sitting in garage waiting for attention

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eddiecross
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#31 Re: Covered Headlight Conversion S1.25

Post by eddiecross » Wed Dec 15, 2021 12:52 pm

Thanks people.
I have got it pretty close now. Down to about 1/2" gap at the very front. Sides now fine
I am using 10/32 bolts 1 1/4" long:
One each side of the back of the scoop fixed into captive nuts on the scoop
One bolt in the centre fixed to the headlight panel with a nylon insert nut so it can rotate and engage with the middle captive nut in the scoop.

This allows me to move the scoop back and forth on the centre bolt with a socket to close the gap at the front (sides are fine)

Now gone to 2" 10/32 bolts in the middle to hopefully close the remaining 1/2" gap.

I'll press on with this method and check out Chucks site if I am still getting issues.

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Regards
Eddie
67 FHC

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keithmac
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#32 Re: Covered Headlight Conversion S1.25

Post by keithmac » Wed Dec 15, 2021 3:38 pm

Hi Ed,
Its looking good.
I am taking notes. Thanks for trouble shooting problems I will soon encounter and the great pics too. What paint did you use on the scoops?
Regards,
Keith
Early 1967 S1 OTS, 1952 MG TD

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eddiecross
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#33 Re: Covered Headlight Conversion S1.25

Post by eddiecross » Wed Dec 15, 2021 10:53 pm

Hi there Keith,
I can't take any credit for that. Courtesy of a previous owner I picked them up from.

I think they should also have a drain hole at the rear by the centre fixing. Image I found...
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All the best
Eddie
67 FHC

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#34 Re: Covered Headlight Conversion S1.25

Post by eddiecross » Fri Jan 14, 2022 11:49 pm

Now got the scoop in the correct position.
I attached 10/32 2" long bolts to the 3 fixings as there were already captive nuts fixed to the back of the scoop.
For the centre bolt, I added a nut and washer about 1" from the scoop flange to lock the scoop in place.
Landed it about right as there was previously a gap at the front- need a 2" bolt to get the scoop far enough forward.
Was then able to centre the scoop by tightening the other 2 bolts from behind the diaphram panel.

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keithmac
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#35 Re: Covered Headlight Conversion S1.25

Post by keithmac » Sun Jan 16, 2022 10:56 pm

Hi Ed ,
Thanks again for posting. Are you using spacers on the sugar scoop bolts or double nuting them ( or both )
Here is where I am to date. Still waiting on parts, they appear to be " covid delayed"
Cheers,
Keith
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Early 1967 S1 OTS, 1952 MG TD

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#36 Re: Covered Headlight Conversion S1.25

Post by eddiecross » Thu Jan 20, 2022 8:49 pm

Hi there Keith great to hear from you. Let me know if I can help with pars/suppliers from here
Really simple in the end.
3x 10/32 2" long bolts in each of the 3 holes in the sugar scoop (which have captive nuts fixed to them) with the threads facing the headlight panel.

On the centre bolt I threaded a nut+penny washer about 3/4-1" away from the scoop (could use a spacer instead).
On the other two bolts I left without any spacers or nuts as you can put them in tension from side to side to centre the scoop.

Dropped in the scoop and I got lucky as the centre bolt spacing was bang on and the long threads made locating the three holes easier than with the shorter bolts.

The 1st couple of times fitting and removing the scoop is really tricky but by the 20th attempt you get the hang of it!

Am working on the passenger side scoop now. A couple of the bonded supports were loose so they are off and cleaned awaiting refixing. Some usual aweful filler repairs under the bonnet but only surface rust.

Notes:
Align chrome bezel- bend to shape and mark outline and holes. The top 2 holes will probably have no metal to mark to- add a tab with masking tape.

Drill lower holes- use a smaller drill and screws than the final ones

Trim the new flanges to fit. I decided to join them at top and bottom so trimmed them so they overlapped. Top join helped close the wing gap

The top inner and outer flanges needed to be pulled out so the step was about 1/4" out at the top on mine.
This allowed drilling holes for the bezel that are on the outside of the step

Tack weld in a couple of places for trial fitting. Drill the 2 holes at the top. Again using smaller screws than final ones in case you need to move anything

As long as the bezel fits correctly and covers the rivet holes from the old headlamp scoop you should be ok.

I am using the plastic lenses which have plenty of give.

I used tack welds all round at about 2" centres with tape and soaked rags to protect the paint. I could have added pop rivets but the flanges were secure and tight to the panels on the inside edges (fit is spot on) .
Also, the scoop did catch on them at the front when I fitted the drivers side scoop.

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67 FHC

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