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AU xr headlight replacment on the cheap- done 

 

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 Post subject: AU xr headlight replacment on the cheap- done
Posted: Mon May 16, 2016 12:41 pm 
Technical Contributor
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Age: 35

Posts: 17

Joined: 11th Feb 2016

Ride: AU S2 black manual XR8 Ute

Location: Perth
WA, Australia

hey guys, thought id replace the headlights in my au xr8.

the new xr8 ute i picked up had 3x cracked lenses and all where fairly pitted and generally s**t condition.

didnt realise that availability was a problem till i started looking for replacments.

nothing wrong with twinlights products i just didnt wan to spend 800 on new headlights so i thought id wing it and see what happens.

this is my my list of parts i started with:

2 of 5 3/4 (146mm) Headlamp Housing, Open Back (72186) AU$30.96
2 of 7 (178mm) Headlamp Housing, Open Back (72190) AU$36.36
1 of H4 7 (178mm) High/Low Beam Halogen Headlamp Conversion Kit - 12V 100/55W (72040) AU$107.20
1 of H1 53_4 (146mm) 12V 100W High Beam Free Form Halogen Headlamp Conversion Kit (72014) AU$113.19
________________________________________
SubTotal AU$287.71
Flat Rate Shipping Standard 1 - 3 Business Days AU$12.00
Total AU$299.71


i picked these up from nold trading online, they where on special

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so after i removed the headlight housing and lenses i thought this was going to be too easy, just drill out the spot welds on the old lens and epoxy them onto the new ones

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just lining them up before attaching

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attaching with some epoxy

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now i will say that this failed miserably lol

the tags just popped off when i tried fitting them, i tried 3 times with different products to attach them, even got the die grinder to scuff the trim around the lens and they still just popped off still.

this was depressing to say the least but in true personal fashion of make it work i proceeded on.

option 2 was to attach the housings i purchased to the old surrounds somehow.

option 3 was to go custom sheetmetal surround the same as twinlights ones he sells.


back onto option 2.


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after a bit of staring and measuring i decided it would be a pretty good fit with the lights spaced out the right distance to match the factory ones if i could get the mounting plates flush with the housing.

if you are going to attempt this take a bit of extra time to ensure the lights will be oriented in the correct position as in rotation of the lens ie, top at top in final bolted up position, mine a the tiniest bit off but it isnt noticable

for the small lights i had to remove a trim to make it fit, just used the jigsaw

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and attached it where i could, note the provisions for the adjustors

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that was a winner so onto the big one, the housing is quite a lot bigger on this one so i needed to trim the base quite a lot to make it fit onto the plastics
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just used the cut off disc in old trusty


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alot better fit now

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headlights must be correctly adjusted before refitting the front bumper as the adjusters are on the front of the housing, you could muck around and get it working from behind but i was happy to adjust them properly first then fit the bumper



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done

ill put up some final pics after i was it :lol:

Last edited by shaunbags on Tue May 17, 2016 7:42 pm, edited 1 time in total.

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 Post subject: Re: AU xr headlight replacment on the cheap- done
Posted: Tue May 17, 2016 9:56 am 
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Posts: 14510

Joined: 7th Nov 2004

Ride: ford falcon au3 xr8

Location: a shit suburb in sydney
NSW, Australia

that gives hope for those who cant find decent au xr lights..
hopefully we dont loose those pics over time..

thats worthy of making it a sticky and technical contributor status..

awesome work mate.
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 Post subject: Re: AU xr headlight replacment on the cheap- done
Posted: Tue May 17, 2016 4:13 pm 
Getting Side Ways
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Posts: 2445

Joined: 5th Nov 2004

Gallery: 7 images

Location: Brisbane
QLD, Australia

The Twinlight XR replacements with Lenses are 325 a side for AU's.
Ive had two sets of twinlights now, and their work is very highly rated. Metal brackets etc. They'll bolt straight on with no work.

They sell just the brackets for $185 each. For those that arent as good at hacking things together, theyre good options.

Glad this worked out though. Nice to see people doing what it takes to keep the older cars going.
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 Post subject: Re: AU xr headlight replacment on the cheap- done
Posted: Tue May 17, 2016 7:31 pm 
Technical Contributor
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Age: 35

Posts: 17

Joined: 11th Feb 2016

Ride: AU S2 black manual XR8 Ute

Location: Perth
WA, Australia

cheers troy,

Nigel wrote:
"For those that arent as good at hacking things together........"



yes it was a hack job lol, bit like a s**t speaker install....... :roll: i was fully prepared to make up the mounting brackets just for a challenge and an excuse to play with the tig welder.....ill wait till i do my stainless airbox i suppose... :D
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