Before I move on to the next stage of the front suspension (dampers) I thought it would be worth a quick recap of the front headlamp wiring. Here’s an exploded view of how I wired up the headlights and indicators.
Black and green wires from the indicator go through the nut, washer, bracket and indicator cone. In the picture I’ve shrinkwrapped these wired to this point.
The black wire heads up through the hollow headlamp bolt, black rubber grommet and is connected to the grounding screw in the headlamp bowl.
The green wire is folded over at the top of the shrinkwrap runs back through the indicator cone, bracket, washer and nut. The wires coming out of the headlamp thread down through the black rubber grommet, hollow bolt, indicator cone, bracket, washer and nut.
These wires then feed though into the stem of the bracket and through the chassis and into the engine bay when the bracket is mounted. You need a grommet where the wires enter the stem of the bracket, and one in the chassis mount.
I found out at this point when first assembling the lights, that my brackets didn’t fit, so if you are about to try this yourself, dry-fit the brackets first.
The holes failed to line up, and as mentioned in my previous post, Derek recommended running a drill through the holes to widen them out. I didn’t feel this was the right thing to do and asked Blatchat the question. Jim123 came up with the suggestion of tweaking the u-shaped flange to allow the holes to align.
This worked perfectly for me and much less invasive than drilling. Thank you again Jim.
After a quick tweak to the flange with a screwdriver, I split a grommet in two to make two semi-circles and inserted the two halves into the stem hole, around the wires. A drop of superglue holds them in place.
Finally, I was fitting the upper front wishbone. I drove the rear bolt in first, then followed with the front bolt while supporting the headlight bracket. The nut on the front bolt is very tight to the paintwork, but a bit of care and firm pushing on the bodywork got the bolt past the IVA strip and in position.
It’s starting to look like a car.