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Hey guys, I decided to do a write-up on my round headlights conversion. I know there is already one by monkeyracing about making some with Rabbit parts, but since I couldn't find Rabbit headlight buckets (all the junkyards sent their Rabbits to the crusher) I settled on Golf GTI MK2 headlights:
But like I said in another post, the GTI headlights are not sealed beams; it's a headlight with tabs on the reflector, with the adjusting screws going through them to the metal bracket. And best of all, the bulbs are 9004s, like the Festiva, so if you get a nice set, just find a way to mount the brackets on you Festy, plug them in and you're done. But the set I got for real cheap had a cracked lens and the lenses were so aged they looked like they got sandblasted, and I already had brand new 7" halo headlights collecting dust. So I measured and while the GTI headlights may be listed as 7", they are more like 7,5". So the 7" H4 conversions you see for sale on ebay fit perfectly into a GTI reflector, which is what I did, so here's the how-to.
-First, get some gloves, glasses, and a shirt (not a t-shirt) and using a punch and a hammer, break the glass lens, and make sure to get all the glass and hardened adhesive off. The remaining glass and adhesive comes off easily with a punch and hammer. Also remove the black metal shield that goes over the bulb, inside the reflector. You should be left with this:
-Next, cut away the bulb's socket, up to between the bulb shield's mounting bosses, like this:
-Then, you have to grind away the inside ridge were the lens used to sit:
After:
And finally, epoxy your 7" H4 conversion of choice in the GTI's bucket, but making sure you have enough room in the back to remove the boot if you ever need to replace the bulb, applying the glue on the lip where the original lens used to sit, clamp everything down and let dry:
-And here's the final product!!!
I'll have them mounted on my car in the next few days, so I'll add another part soon, which will be about mounting them, had making the clear covers.
But like I said in another post, the GTI headlights are not sealed beams; it's a headlight with tabs on the reflector, with the adjusting screws going through them to the metal bracket. And best of all, the bulbs are 9004s, like the Festiva, so if you get a nice set, just find a way to mount the brackets on you Festy, plug them in and you're done. But the set I got for real cheap had a cracked lens and the lenses were so aged they looked like they got sandblasted, and I already had brand new 7" halo headlights collecting dust. So I measured and while the GTI headlights may be listed as 7", they are more like 7,5". So the 7" H4 conversions you see for sale on ebay fit perfectly into a GTI reflector, which is what I did, so here's the how-to.
-First, get some gloves, glasses, and a shirt (not a t-shirt) and using a punch and a hammer, break the glass lens, and make sure to get all the glass and hardened adhesive off. The remaining glass and adhesive comes off easily with a punch and hammer. Also remove the black metal shield that goes over the bulb, inside the reflector. You should be left with this:
-Next, cut away the bulb's socket, up to between the bulb shield's mounting bosses, like this:
-Then, you have to grind away the inside ridge were the lens used to sit:
After:
And finally, epoxy your 7" H4 conversion of choice in the GTI's bucket, but making sure you have enough room in the back to remove the boot if you ever need to replace the bulb, applying the glue on the lip where the original lens used to sit, clamp everything down and let dry:
-And here's the final product!!!
I'll have them mounted on my car in the next few days, so I'll add another part soon, which will be about mounting them, had making the clear covers.
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