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Thanks to B.C. and Goldy for tips on rebuilding a headlight housing assembly, as it turned out I needed it!
I found all three of the housing bolts, 2 out of 3 of them didn't come loose and just spun (I guess I needed to use PB Blaster every night for days prior to trying these!). So I went out and bought the new nuts and bolts needed and I took a plastic pen and took the innards out to use the plastic tube as a bolt head extender as in B.C.s tip avoiding epoxying new bolts in.
when I removed the housing and attempted to disassemble the bucket from it I broke 2 of the 3 adjuster molds (one with the spring clips holding the adjuster screws into the plastic molds). I super glued the one that didn't have a spring clip and used the "fiberglass matting and resin" idea from goldy to mold myself a replacement molded retainer for the clip, a hack saw and a drill was all that was needed to replicate the holder.
All in all I have a much clearer headlight now (after trying oven cleaner I went with the wet sanding method - 600 grit sand paper and then some plastic polish). And a much better silicone seal on the lens which should keep out moisture in the future.
lost the nut for the one housing bolt that didn't break, spent far too much time but learned a lot about fiberglass and plastic, also must have busted the connector to my parking/turn signal bulbs because they are not working now (that connector was a pain to disconnect!)
but I got the job done, not as good as a new set of e-codes but not as expensive either!
thanks to all who helped me with tips to see this thing through!
jack
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Bad Blue, '86 245, 250,000 mi., Columbus, Ohio
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