rewiring headlight buckets

[Tom Overfield]

For those that are going to rewire headlight buckets (on a 40 0r 41 anyway), here is the process I used. Thanks to John Murphy for confirmation on the process.

Photo #1 shows the headlight bucket and what is left after tearing the old loom off. You can pull on the old loom until the cows come home and then some but it will not move.

#2 is inside the bucket housing showing the three tabs that will need to be straightened to release the two parts that hold the loom solid.

#3 is the tool I modifyed to straighten these tabs, there isnt a whole lot of room in there to work. I sharpened the one end to a knife edge to be able to get under the tabs.

#4 This is the placement of the tool, but you need to move it closer to get near the edge of the tab, I held the tool with a small pair of vice grips as that will give you more room to tap with the hammer and force the edge of the tool under the tabs. They are tougher than they look.

#5 Photos showing the tabs bent up and tapped down lightly freeing the two pieces. You will probably find the two pieces are frozen together solid and will not come apart. Have no fear, grab your bernz-o-matic and heat the outside part, if you are lucky like me, your loom will now catch on fire and fill the entire area with stinky smoke. Blow out fire, then pry the outside part down and away from the bucket. This will now allow you to remove the old loom.

#6 This shows the two pieces almost apart

#7 apart

#8 This shows how the two parts and loom go together, the loom fits inside the first piece shown, it fits flush with the top edge. This piece is then inserted into the headlight bucket from the bottom. Now place the bottom piece into a vice while it is in the bucket and close the jaws just enough to allow the ridge on this part to rest on the top of the jaws of the vice. Spray some silicon inside of the loom from inside the bucket then force the remaining piece inside the loom and down onto the tabs. Once you are sure the two pieces are together tight and the bottom piece is tight against the bucket, go ahead and bend the tabs back down locking the whole assembly into place.

Now pull the new wiring through the loom from inside the bucket and down and you are finished.

Tom

[40ZephSedan]

That is a project I have coming up too, so this info you supplied will be very helpful - thanks for your time to pass that on. That blue Zephyr in the background of one photo looks familiar, almost same color as mine! Would like to see the rest of it! Paul

[Tom Overfield]

Here it is Paul,,,,close but no cigar exactly yet,,but very close.

Tom

[40ZephSedan]

Very Nice. Thanks for posting, that's a beaut! Looks like front end really raises up without the weight of the engine.