The Ford Barn

Chris Haynes · 12-18-2017, 11:58 PM

I'm trying to get my headlight conduits/wiring to connect to the headlight. It will "Almost" compress far enough to allow me to connect the conduit, but not quite. Of course every single part except the headlight bucket is repop. Looking for suggestions.

TIA

Mike V. Florida · 12-19-2017, 12:39 AM

Quote:

Originally Posted by Chris Haynes

I'm trying to get my headlight conduits/wiring to connect to the headlight. It will "Almost" compress far enough to allow me to connect the conduit, but not quite. Of cou, se every single part except the headlight bucket is repop. Looking for suggestions.

TIA

Careful sanding and filing may be necessary.

slammin · 12-19-2017, 02:02 AM

I had the same problem with my right headlight. The left one went together fine. I thought it might be the length of the headlight wire plug. It might help to sand a little off the bottom end, the end that goes into the conduit. It turned out that the socket in the bottom of the headlight was loose, allowing it to move into the pod enough that you couldn't twist the conduit connector to engage the detents. I had to dis-assemble the headlight and tighten it.

Dan Partain · 12-19-2017, 02:12 PM

First take the wires out of the conduit and try these in order.

1. Try fitting just the ferrule on the headlight. The nibs on the ferrule for the twist lock vary on the repros and can make twisting them on difficult or impossible.
2. Try fitting just the ferrule and the conduit onto the headlight. Some of the repro ferrules have a little too small of an opening in the back to allow the conduit to drop down far enough on the flared part of the conduit. You may need to open up the opening in the back just a little bit to allow the flared part of the conduit to fit better.
3. Try fitting the assembly with the wires and connector.

duke36 · 12-19-2017, 02:47 PM

Some of us abandon the stock wiring connectors in favor of splicing more modern connectors inside the headlamp behind the reflector which allows for a more positive connection and adjusting the conduits. Some repo's are 1/2" and others are 9/16". As in other posts, make adjustments so the conduit end can be a tight friction fit, even using some thin tape to help close the fitting gap (doesn't affect the ground path)..

Chris Haynes · 12-19-2017, 08:38 PM

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Through main force and awkwardness I finally got them on. :-)

12-18-2017, 11:58 PM	#1
Chris Haynes Senior Member Join Date: May 2010 Location: Camarillo, CA and Pine Grove, CA Posts: 2,832	Assembling headlight conduits I'm trying to get my headlight conduits/wiring to connect to the headlight. It will "Almost" compress far enough to allow me to connect the conduit, but not quite. Of course every single part except the headlight bucket is repop. Looking for suggestions. TIA __________________ 1921 Runabout 1930 Tudor Early 1930 AA Speed costs money. How fast do you want to go?

12-19-2017, 02:02 AM	#3
slammin Senior Member Join Date: Aug 2017 Location: Fruita, CO Posts: 281	Re: Assembling headlight conduits I had the same problem with my right headlight. The left one went together fine. I thought it might be the length of the headlight wire plug. It might help to sand a little off the bottom end, the end that goes into the conduit. It turned out that the socket in the bottom of the headlight was loose, allowing it to move into the pod enough that you couldn't twist the conduit connector to engage the detents. I had to dis-assemble the headlight and tighten it. Last edited by slammin; 12-19-2017 at 02:26 PM.

12-19-2017, 02:12 PM	#4
Dan Partain Senior Member Join Date: May 2010 Location: Hangtown, CA Posts: 556	Re: Assembling headlight conduits First take the wires out of the conduit and try these in order. 1. Try fitting just the ferrule on the headlight. The nibs on the ferrule for the twist lock vary on the repros and can make twisting them on difficult or impossible. 2. Try fitting just the ferrule and the conduit onto the headlight. Some of the repro ferrules have a little too small of an opening in the back to allow the conduit to drop down far enough on the flared part of the conduit. You may need to open up the opening in the back just a little bit to allow the flared part of the conduit to fit better. 3. Try fitting the assembly with the wires and connector.

12-19-2017, 02:47 PM	#5
duke36 Senior Member Join Date: Jun 2015 Posts: 1,414	Re: Assembling headlight conduits Some of us abandon the stock wiring connectors in favor of splicing more modern connectors inside the headlamp behind the reflector which allows for a more positive connection and adjusting the conduits. Some repo's are 1/2" and others are 9/16". As in other posts, make adjustments so the conduit end can be a tight friction fit, even using some thin tape to help close the fitting gap (doesn't affect the ground path)..

12-19-2017, 08:38 PM	#6
Chris Haynes Senior Member Join Date: May 2010 Location: Camarillo, CA and Pine Grove, CA Posts: 2,832	Re: Assembling headlight conduits Sponsored Links (Register now to hide all advertisements) Through main force and awkwardness I finally got them on. :-) __________________ 1921 Runabout 1930 Tudor Early 1930 AA Speed costs money. How fast do you want to go?