We can also improve the electrical contact inside the bayonet socket where it connects with the bulb. Photo 9 is the original crimped terminal. Since a new wire needs to be included in our reassembly and long enough to travel to the car's light controller, we decided to reuse this original terminal. Photo 10 shows it being salvaged and reused, Photo 11 is the finished soldered terminal and Photo12 has the new wire threaded through the round insulator and spring before being inserted into the bayonet socket. As the front bezel is now fitted with its glass lens and retainer clip, it is ready to marry the front bezel to the shell. The front bezel is secured using a new chrome plated oval screw from the back of the shell. Check that there is ample clearance between the retainer clip and the wire coming through the bayonet socket (Photo 13) and the power wire does not get pinched between the retainer and the shell. Photo 14 shows the finished light being tested using a 6 volt source (Photo 15). These cowl lights can now be set aside until we're ready to mounted them on the car.
1. Uvira Laser Optics,
P.O. Box 1137, 310 Pleasant Valley Road, Merlin, OR 97532
Phone (541) 474-5050
2. Chrome hardware:
Photo 1 — The three components of the cowl lamps as they came back from the plater; left to right they are the front bezel, the bracket, and the shell.
Photo 2 — Keeping things organized makes a world of difference when reassembling parts like these cowl lamps. Each envelope contains the cowl lights hardware, socket and glass lens.
Photo 3 — Shown is a 6-32 Truss Head Threaded Rivet as a possible candidate for reassembly. It fits inside the hole and covers the hole well, and despite its low profile, it just doesn't seem to do this brackets justice.
Photo 4 — Shown is a 6-32 Round Head Threaded Rivet as the other choice. Its fits into the recessed hole well and the round profile is a match for the original rivet. All six round head threaded rivets are polished before using them for assembly.
Photo 5 — A thin bead of sealant is applied to the bracket's mating surface before adding the shell and the inside brass sheet retainer.
Photo 6 — Inside view of the cowl lamps showing the threaded rivets, flat and split ring lock washer and nut. A nut driver quickly twisted tightens the threaded rivet fastener. Notice the machine threads are longer than need to be and the excess threads are easily removed using the small cut off wheel in our rotary tool arsenal.
Photo 7 — The cowl light reflectors were recoated several years earlier and carefully stored waiting to be assembled.