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Thread: Headlight bucket removal

  1. 12-01-2014, 03:54 PM #1
    maverick
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    Headlight bucket removal

    Any tips on removing and installing a headlight bucket on a lwb fender ?
    Thanks in advance
    Regards
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  2. 12-01-2014, 07:05 PM #2
    Slcarr
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    Find all the spot welds, sand with 150-220 sandpaper to mark them out. Use a air die grinder with a round metal cuttingbit, the smaller the better. Go around in circles with die grinder where spot welds are until you see a brown ring (rust) try to keep cutting area as small as possible at spot weld. The bucket will still not come out easy as rust has swelled both metal surfaces. Stand up on end so bucket is up and spray penetrating oil in crevice, let soak, maybe overnight. Use a dead blow hammer from back side and force bucket out, try not to dent it, they can be stubborn.
    Are you putting the same bucket back in? If so clean both matting surfaces really good with wire brush on drill. Use metal prep on surfaces and wipe off with damp rag (other stronger acids work better but hazardous). Put bucket back in to exactly the same spot and braze spot welds where cut with flux coated brass. The brass takes far less heat and tends to sweat into surrounding steel.
    If you are putting a new bucket in drill 1/4" holes in bucket, measure carefully as you need to leave room for rubber seal between headlamp assembly and fender. Clean all mating surfaces as before and braze in.
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  3. 12-03-2014, 02:01 PM #3
    robmog
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    an old posting of mine, with above info you should be good to go.
    http://www.early911sregistry.org/for...et+replacement
    bob moglia
    '72 E sunroof coupe
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  4. 12-03-2014, 05:21 PM #4
    maverick
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    thanks fellas
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