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Sorry for the big delay and keeping you all in suspense. I was gone to Vancouver just after I got the lights in, then couldn't get a digital camera until now. Here are pictures and some description of this project:
Here's what it looks like minus one homemade cover on driver's side. Note how the middle square "high beam" lights look weirdly aimed. It's because the huge driving lights cover the middle of the road, so I use the highs to point more to the sides. Anyways, here's the picture:
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Here's Just the front left light assembly with my homemade cover:
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Here's the top of the driver's side assembly, with no cover. Note, similar to Kane's conversion, I used 2.5 inch "L" brackets to bolt up the corner lights. Pretty easy really:
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Driver's side assembly. Note the mounting screw in the top right. I had to drill ALL the holes into the headlight plate, but there were some available behind some of the spots on the car's sheetmetal. In the top right bolt, I used a large machine screw then a big washer so there is a "gap" in-between the metal pieces. The second picture is that machine screw, except on the passenger side assembly:
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The other 2 bolts are just a matter of finding the right spots and drilling. I know someone might say "Only 3 bolts?!?!" but with three bolts, the assemblies are FAR more stable than my old stupid bucket lights. Here's the other two bolts on the passenger side assembly:
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Now you might say "Well, that's nice, but is there any power behind the lights?" The answer is yes. I have relays running all the lights on my car. Here are the relays for the main headlights (there is a cover for them):
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So was it worth it? YES YES and YES. The improvement is literally night and day. I can see so much better with these sealed beam lights, and the lows are just the sylvania high-output performance type lights which I got at Canadian Tire for $16 each. My light output on "low" is probably double my old high beams with the buckets, and the light is VERY nicely distributed. After aiming the lights, I can see even better. The whole deal only took me a few hours to bolt/drill up. I have spent more time making covers for them (out of sheet aluminum). If you're looking for a direct, bolt-on replacement for lights, this is not for you, as the 80-85 light surrounds will not fit and you have to drill some holes. I also removed the chrome trim on the grill, which I think looks nice anyways. Well, I'm sure I didn't answer EVERY question, so feel free to ask. Happy bricking!
Nate Gundy
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'86 240DL sedan, 260K miles, M46, K cam, 25/21mm sways, 260 front and wagon rear springs; http://valvespringcompressor.weblogs.us/
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