Inopt Headlight Door Tutorial - Corvette Forum
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post #1 of 3 (permalink) Old 09-26-2014, 12:06 AM Thread Starter
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Join Date: Sep 2014
Location: Pensacola, FL
Posts: 18
Inop Headlight Door Tutorial

Hi, just joined and just bought my first one this morning. The headlights hadn't been turned on in 13 years guessed it..............they only open half way. Well one goes all the way but struggles to get there. The port side doesn't close all the way either.

Can someone point me to a headlight door repair tutorial or enlighten me on what it takes to get them operating properly?


Last edited by shootnstarz; 09-26-2014 at 12:20 AM.
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post #2 of 3 (permalink) Old 10-05-2014, 02:39 PM Thread Starter
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Location: Pensacola, FL
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Appreciate the help.

I finally found some youtuber videos on repairing the headlight doors. The one I fixed had been previously tampered with and somebody had replaced the 3 little plastic bushings with three 1/4" steel nuts. The gear was also stripped so I ordered 2 replacements with bearings and gaskets.

While I had this headlight assembly disassembled I noticed the plastic bushings on each end of the accuator linkage were worn almost to nonexistence. I found some replacements on feebay, for about $30 a set !!!!

So instead I dug into my collection of brass tubing and found one that slipped inside another and the ID was perfect for the snap ring studs. The OD was a little large to fit in the bushing hole so I used a drill and "machined" the piece down to the perfect OD to fit.

So now I have brass bushings instead of plastic and there's very little slop in the linkage. While I have it all apart I removed, sanded and painted the headlight bucket, had a lot of surface rust inside and out, and the bracket got a new coat of paint too. Now if my gears would just show up I'd be back to the reassembly stage.

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post #3 of 3 (permalink) Old 10-06-2014, 03:12 AM
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I believe there are tutorials on Youtube...
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