problem with alignment/gaps of front light units

[frank912]

Hi,

I am currently restoring a '72 911 sunroof to a more than decent standard.

All the bodywork has been done and we are currently at the stage of test fitting everything. Here comes the problem...... I have a lot of problems with aligning the front light units perfectly. Installed with new aftermarket rubbers the lenses "stick outside" of the body. If I trim done the lenses fit much better.

I am looking at this with a magnifying glass, because I would like to have a perfect alignment of light unit/grill both the same (left and right, with equal gaps everywhere).

And.... this has not been achieved unfortunately. One light unit is aftermarket and does not fit perfectly in the aftermarket fender in combination with the gril. Without it is fine, but with the gril it does not work (they cross each other).

This made me look better to my other F models and to be honest..... neither one has a perfect fit. Am I looking at something which is not achievable? If achievable..... are there any tips/tricks? Now is the time to make alterations if needed. Don't want to end up just using filler to get the perfect gap.

Thanks a lot in advance.

Regards, frank

[jim amato]

I would obtain genuine parts, that could be part of the problem

[frank912]

Hi Jim, Thanks for your reply. That's what I thought as well. But given the current state, I would prefer to not replace the aftermarket fenders.....

I was hoping for some magical tricks :-)

Regards, frank

[steve shea]

If the rubber is the cause you can trim as you suggested. But some of the new rubber may be too fat and or stiff. One trick is to live with it and gradually tighten the screws as the rubber takes a 'set'. New rubber is often the cause of poor fitting panels, hard to close doors etc. Another thing for the light fixture or grill is to take a rat tail file to the offending hole(s) and enlarge accordingly to give more up down and back and forth movement. Many areas,especially on 356 cars, had elongated holes for just such adjustment. Given that you have a mix of aftermarket parts, the file, some shims and trial and error can do wonders for fit issues. But not seeing the car it is only advice, take it or leave it. Good luck.

[frank912]

Hi Steve,

Thanks a lot for your help. I will schedule a 'fiddling day' for this then!! Regards, frank

[Eminence Gris]

You can bend the mounting tabs back, of course, but I have also used a Dremel on the 'high spots' on housings in order to get them into the fender. The fit is rarely perfect as you are matching 2 compound curves. The problem I've run into most commonly is a gap in the center of the housing - where it protrudes beyond the curve of the fender. Start without the seal on the housing and get it deep into the opening. As Steve says, you may benefit from shaving the back of the seal - especially at the rear of the housing.

[frank912]

Cool! Thanks for the advise!!

Have a great weekend.

Frank