Headlamps

Just a side project that needed to be done. Since this '66 galaxie 500 XL shares the same headlamps as our '66 LTD I thought I would do them both. So here we go.

I started with the bulb retainers. I had a bunch of these headlamps so in order to pick the best parts, they all have to be cleaned and inspected. In other words loads of polishing is in order.

I did the 9 best rings then picked the best 8 of 9.

The same deal with the bezels.

Then I found even more of these after I shot this.

I stripped and powder coated the support plates for the headlamps as well as all the headlamp buckets. Now for the headlamps and buckets. The headlamps I am using is a composite glass and aluminum assembly. The only problem is the aftermarket composite headlamps only come in Low/High so I had to use the extra low/high buckets from all the spare headlamps assemblies and ditch the high beam only buckets because they are keyed to the bucket differently.

I originally bought these to use a long while back as these were the only composites I could find at the time. I thought these were too garish to have exposed all the time so I ended up using these on the '68 XL, since when they are off the headlamp doors are closed and hide these.

Then I found composites that look more like the original style headlamps so I used those.

The one thing that dies in these headlamps are the plastic threads for the adjusters. These license plate nylon threaded blocks work really well for this.

Just make sure you get the one on the right and not the left as they sell both. The one on the left is cheap crap.

Snap them in from the backside and Bob's your Aunty. I like to run a tap through them to make threading the adjuster bolts in easier.

Agh the aftermarket strikes back again. Sooooooooooo when you use the bulbs as is they do not sit level in the headlamp bucket.

Take a look at the right and you'll see how they sit, they are tilted in the bucket and it looks cheesy. The headlamps on the left are corrected.

To correct them or clock them a few degrees I had to relocate the hump to the left in the locating tabs.

New stainless hardware as the old chrome screws were pitted and chewed up.

And here's two sets ready to go. At first glance you wouldn't know they are composite headlamps with 100 watt low beams and 140 watt high beams. They use standard H4 bulbs. And yes according to FMVSS 108 you can run 4 low beams if you wish. About the only limits are the intensity at certain beam angles from a federal point of view.

I run these same wattage bulbs in the '68 XL and I love the bright projection on the roads even on low beam, sadly it just keeps up with new modern vehicles for low beams but enters stupid bright on high beams with 540 watts. You do have to use ceramic sockets with the high wattage lamps.

More to come.

Cheers