Attaching the turn signals is the easiest part of the project. A simple L-bracket can hold them properly in place, as you can see in these pictures.
Mounting the headlight buckets within the front end isn't extraordinarily difficult, either. As you can see in this picture, the quad round headlight buckets can be mounted fairly easily with three anchors. The single rounds might be a bit easier, simply using more L-brackets and some of the holes that are already there.
The absolute toughest part of a headlight conversion is making things look good. There are those brackets that are sold for Volvo Trucks, but they're exorbitantly expensive and probably won't fit whatever homegrown mounting method you use. I wouldn't risk getting something expensive and unusable, at least.
I've yet to see what I consider a "satisfactory" single-round headlight conversion in a post-1986 Volvo. I mean no offense to Kane or the others who have done this conversion, but even with the solutions that they've used, the fillers for the front ends leave "gaps" in the front end of the car. Now, everything is covered and somewhat protected that should be (at least with Kane's plastic frames), but one can still see "inside" the front end. I have not seen if tjts1 has developed a suitable filler piece yet, so I don't know if he found something that works well with 7-inch rounds.
The quad headlight setup, I surmise, is a little bit easier to adapt to the post-1986 front end. However, I'm not sure how the single-round headlight pieces would look in such a car. Once you pull the grille and headlights, the front end is pretty much wide open--one very well might be able to anchor the GT grille in and use the headlight trim pieces. However, I am under the impression that the quad headlight front end is easier to use because each piece is roughly the size of what it's replacing. The filler pieces are pretty close in size to the space of the Aero lights, but I don't think that my conversion is doable with a stock 240 grille, and be aware that there I still have overlap.
I personally prefer the quad round headlight because, well, it's the one I've done, but also I think it provides, in the end, the most light. I've already got E-codes for the high/low beams, and I might get some Cibie H1 high beams with an internal yellow cover in April (my birthday is in April; I'm currently running sealed high beams that are good enough, but I want better). The seven-inch E-code beams are an unequivocal improvement over the Aero headlights, but I think the 5.75'' quad round lights are the best since they've got a (nearly) as good beam pattern and brightness on lows, and two headlights (instead of just one) shining on high beams. I love it.
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'89 244 GL -- 108,995 miles (see profile for info on car)
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