1968 Ford XL Hide-A-Way Headlamps Overhaul and Lumen Upgrade : 06 part Six


2023, November 14

1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 - 11

I have 3 extra vacuum servos for the '68 should the rubber diaphragm die. These '68 vacuum servos are getting extremely hard and expensive to find. Worse comes to worse then I can always switch it to electric (use Ford Probe headlamp motor), but to do that correctly it's loads of machining and fabrication to do it right.

The small fascia retainers kind of look like a license plate retainer that I used on the headlamp adjusters, but Ford really engineered themselves into a corner with that tiny intricate retainer. It doesn't snap in. Friction holds it in till the screw is screwed in then it splays the little little pillars out holding it in.

Ha, maybe I should have checked to see if Ken and Barbies car license plate retainers would have worked

Turns out all 4 (3 spares) of my servos leak. It's just not worth the hassle of dealing with vacuum leaks and a noted problem with new seals. I am going to try the electric conversion using a Ford Probe headlamp motor. It is certainly not an easy conversion when dealing with backlash, total travel of the Probe motor and the mechanical stops of the headlamps themselves.

If the system was well built I'd consider rebuilding it to existing standards, but it's a bit slapdash in my opinion. The worse part is the slow moving headlamp doors under the vacuum system. I find that annoying, along with the wasted space of the large vacuum tank and a bundle of long vacuum hoses. I think someone was vacuum obsessed at Ford during this time, especially with their vacuum operated door locks of the 3rd gens. (rolling eyes). That was another terrible idea.

This is the other side. Dear god this whole project turned tedious if not insidious. You couldn't pay me enough to do this again .

Completed.

Here's the sad grill, headlamps. You'll notice the grills are bent and do not line up. The headlamps aren't terribly bright either.

Better view of some of the damage.

Every time the vacuum system closed the doors you could hear and feel them hammering down from inside. Twas not good.

Time to dig in.

This is the last of the insidious wiring. It's rock hard and crumbles if you bend it. How this car didn't burn itself down long ago defies the odds.

Even the socket were falling apart taking this harness out.

Notice the lower portion of these supports are all bent up.

I do have this complete spare radiator support to draw on parts from, not less forgetting an entire another '68 XL fastback car.

Click here to continue to part 7