Subject: Restoring Headlight Assemblies up to 1967 Beetles
65standard
Officially Full-On Dubber
Posts: 373
Threads: 47
Registered: April 18th, 2009
Member Is Offline
Location: Sydney, NSW
Theme: UltimaBB Pro Blue
Mood: Only when I'm in it.
posted on December 25th, 2013 at 08:48 PM
Restoring Headlight Assemblies up to 1967 Beetles
[size=4]I thought I'd start this thread, as I could find very little information about restoring this type of headlight assembly, as the information
was mainly for the sealed beam units in the US. This restoration also applies to Bosch headlight assemblies made the same way and for Kombis.
Anyway, here's the headlight I started with.
Crusty old thing from about 1964 or later.
The bucket in the photo below is plastic. Yes, Hella replaced the earlier metal bucket to a grey plastic bucket in about 1964. I was in luck that it
was neither cracked or distorted as plastic would become after nearly fifty years.
[/size]
[size=4]Disassembling the headlight assembly and waiting what was in store for me. Care must be taken when removing the spring clips. They can fly outand become lost, or worse, take an eye out. This assembly only had three spring clips installed.[/size]
[size=4]The reflector wasn't in the best shape, and needs to be replated. The chrome outer ring looks better than it does in the photo. The plastic
bucket was in exceptional shape, with very little discolouration to the plastic. The lens is not cracked which is a major bonus.
[/size]
[size=4]The bucket as you can see is intact.[/size]
[size=4]The chrome ring is also in good shape with no dents.
[/size]
[size=4]After a bit of elbow grease cleaning and polishing the parts and renewing what had to be renewed, here is the assembly and final product.
Firstly the lens. Rinsed and then washed with warm soapy water and a sponge with the finest of scouring pads to get as much of the dirt out of the
fluting inside the glass.
[/size]
[size=4]Next is the lens with a new rubber seal.
[/size]
[size=4]Next. The reflector was replated in chrome. Not bad for $45.00 per reflector, and the finish is fantastic. Others try "chrome paint", but it
does not reflect like the chrome. There are even those that try foil glued to the reflector or use aluminium tape.
I know there are those that will say "Silvering" is the only way to replate the reflectors to their original finish as it is about 90% reflective to
chrome's 70%, but the cost is about triple that of chrome, and you're still not guaranteed of a great finish.
[/size]
[size=4]Then we have the plastic bucket cleaned and polished with "Silvo" which is a fine polish for chrome, sliver etc. The discolouration was
polished out, and the gloss restored to the plastic bucket.
[/size]
[size=4]The chrome ring came in for some special treatment being polished with Silvo. The result is fantastic.
[/size]
[size=4]Mounting the lens onto the bucket. [/size]
[size=4]And the finished product. One restored headlight assembly.
[/size]
[size=4]The spattering on the back of the reflector is the chrome from plating. This isn't seen when installed, so it matters very little. To me
anyway.
[/size]
[size=4]The parts that had to be changed or replaced that were missing are:
1. Rubber seal for the lens (split).
2. Rubber grommets for the beam adjustment (hardened and cracked).
3. I bought new spring clips, but they didn't fit. I had spare old clips and reused them (reused the original three and had three spare).
4. Screw and spacer for the chrome ring attachment to the mud guard (missing).
5. Replating of the reflector.
6. I did not refit the internal reflector that sits in front of the bulb, as I run P43 halogen bulbs (60/55W). These bulbs are too long, and give a
better light than the old (45/40W incandescent bulbs)
In total, it took a morning of cleaning, polishing and assembling the light assembly (not including the plating of the reflector) to have a new and
ready to fit spare headlight assembly. I can safely say that the headlight assembly is mostly original and maintains the look and gives a good light.
Is the finished headlight assembly in "concourse condition"? Nope. For my purpose it doesn't need to be, as I use my '65 Bug on a daily basis, and
I just need parts that work well or spares ready to go. If they look better than they work, it's not much value to me.
I hope this helps with those of you that have these types of headlights and gives a bit of an insight into these assemblies.[/size]
[size=4]If it ain't broke, fix it till it is![/size]
vlad01
Compulsive Aussie Vee Dubber
Posts: 4270
Threads: 109
Registered: June 3rd, 2010
Member Is Offline
Location: Kyneton, VIC
Theme: UltimaBB Pro Blue ( Default )
Mood: Side ways
posted on December 25th, 2013 at 09:25 PM
you can buy new hella reflectors from the UK for post and pre 67 ish or when ever the change over year was. I got mine at 50 pound each, well worth
it for German made OEM refectors that are just like the originals
reflectors are actually metalized with few micron of aluminium in a vacuum chamber where they are metalized by aluminium atoms in vapor form.
Then they are seal in a kind of high temp clear chemical coating of some sort to stop the auminium oxidizing straight away being so very thin.
Aluminum reflects around 95% +
I think silver may have been used on much older cars but I can't find any info to support that silver was ever used on car headlights.
Anyway they look good.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE
vlad01
Compulsive Aussie Vee Dubber
Posts: 4270
Threads: 109
Registered: June 3rd, 2010
Member Is Offline
Location: Kyneton, VIC
Theme: UltimaBB Pro Blue ( Default )
Mood: Side ways
posted on December 25th, 2013 at 09:30 PM
here are my hella reflectors I bought to replace the corroded nos ones.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE
65standard
Officially Full-On Dubber
Posts: 373
Threads: 47
Registered: April 18th, 2009
Member Is Offline
Location: Sydney, NSW
Theme: UltimaBB Pro Blue
Mood: Only when I'm in it.
posted on December 26th, 2013 at 01:34 AM
Thanks Vlad. This was just info for those that may have wanted to "restore" their headlights if they're on a budget, but wanted more than the
"chrome in a spray can" or the US style with the sealed beam with the clear glass setup.
My understanding as from what I'm led to believe from older guys in the business is that reflectors were silver sprayed in the older reflectors,
because when you tried "polishing" the reflectors, you'd wear away the silver coating and end up in either the black or grey/yellow undercoat
base.
Anyway, GBP50 plus postage is still over $100 per reflector, and I've been using headlights rechromed for over three years, and they're more than
fine for my 6V system. The original headlights came out with 45W/40W bulbs, and I'm using 60W/55W halogens.
[size=4]If it ain't broke, fix it till it is![/size]
vlad01
Compulsive Aussie Vee Dubber
Posts: 4270
Threads: 109
Registered: June 3rd, 2010
Member Is Offline
Location: Kyneton, VIC
Theme: UltimaBB Pro Blue ( Default )
Mood: Side ways
posted on December 26th, 2013 at 09:50 AM
yeah it works, not the best though. the reflectors get really hot too as a lot of the light energy is absorbed by chrome.
anyway looks like I got them cheaper. I bought mine almost 2 years ago.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE
HappyDaze
A.k.a.: Greg Mackie
Son of Jim - Creator of Good
Superannuated
Posts: 2887
Threads: 141
Registered: June 13th, 2009
Member Is Offline
Location: Southern Highlands NSW
Theme: UltimaBB Pro Blue ( Default )
Mood: Happy enough
posted on December 26th, 2013 at 01:55 PM
With those powerful globes - I assume they're 12v - the lights should be fine. Will you be doing much night driving?
Years ago, I had the reflectors for my vintage headlights rhodium plated.....brilliant!
I'd rather wear a Beetle out by racing it than by polishing it!
65standard
Officially Full-On Dubber
Posts: 373
Threads: 47
Registered: April 18th, 2009
Member Is Offline
Location: Sydney, NSW
Theme: UltimaBB Pro Blue
Mood: Only when I'm in it.
posted on December 26th, 2013 at 05:04 PM
Greg,
They're 6V and do me fine for the night driving I do around town. I can see and be seen. I wouldn't be driving outback or country roads at night,
even with 100W globes on a 24V system.
[size=4]If it ain't broke, fix it till it is![/size]
vlad01
Compulsive Aussie Vee Dubber
Posts: 4270
Threads: 109
Registered: June 3rd, 2010
Member Is Offline
Location: Kyneton, VIC
Theme: UltimaBB Pro Blue ( Default )
Mood: Side ways
posted on December 26th, 2013 at 06:29 PM
Quote:
Originally
posted by HappyDaze
With those powerful globes - I assume they're 12v - the lights should be fine. Will you be doing much night driving?
Years ago, I had the reflectors for my vintage headlights rhodium plated.....brilliant!
I am guessing you got that done as there is no one that can do factory metalizing?
I tried looking for ages for someone who could do it.
Seems the technology doesn't exist in oz.
how well did the rhodium work out?
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE
vlad01
Compulsive Aussie Vee Dubber
Posts: 4270
Threads: 109
Registered: June 3rd, 2010
Member Is Offline
Location: Kyneton, VIC
Theme: UltimaBB Pro Blue ( Default )
Mood: Side ways
posted on December 26th, 2013 at 06:45 PM
oh btw here is vid of the metalizing process if anyone is interested. Similar process for automotive lights, CDs and DVDs reflectors, mirrors,
insulation etc...
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE
silver
Veteran Volks Folk
Dangerous when poked
Posts: 2169
Threads: 162
Registered: December 8th, 2002
Member Is Offline
Location: Sydney
Theme: UltimaBB Pro Blue ( Default )
Mood: In 2 Minds
posted on December 26th, 2013 at 07:50 PM
Quote:
Originally
posted by HappyDaze
I had the reflectors for my vintage headlights rhodium plated.....brilliant!
Hmmmm Rhodium, 45, (102.9100) my favourite
Keeping it real !
modulus
A.k.a.: Peter Hill
Veteran Volks Folk
Posts: 2009
Threads: 76
Registered: July 1st, 2003
Member Is Offline
Location: Melbourne
Theme: UltimaBB Pro White
Mood: modular
Posts: 373
Threads: 47
Registered: April 18th, 2009
Member Is Offline
Location: Sydney, NSW
Theme: UltimaBB Pro Blue
Mood: Only when I'm in it.
posted on December 27th, 2013 at 12:42 PM
G'day guys,
All great input, but prohibitively expensive IF you're able to find someone who will Rhodium plate or metalise something for you.
As stated earlier, this is a budget restoration of the reflector, but still doable with the ever decreasing number of plating shops and lack of
availability of new reflectors unless you go for the (in my opinion) crappy US styled sealed beam clear lens look.
For those that can afford to silver plate, that's great. If there's anyone in the country that will metalise a one-off item or a few items, even
better, but highly unlikely or very remote at best.
For a relatively cheap restoration and reasonably effective, chrome plating is good and has served me well.
In reality, how many air-cooled VW owners do serious night driving in their air-cooled VW's outside of the city lights? If they do, they'll be
having serious spotties fitted.
That's what these forums are all about. Sharing input and ideas, and all appreciated.
[size=4]If it ain't broke, fix it till it is![/size]
vlad01
Compulsive Aussie Vee Dubber
Posts: 4270
Threads: 109
Registered: June 3rd, 2010
Member Is Offline
Location: Kyneton, VIC
Theme: UltimaBB Pro Blue ( Default )
Mood: Side ways
posted on December 27th, 2013 at 03:44 PM
as I stated before. No one in this country does it. only place I could think of is a DVD/CD producer company in Sydney that have metalizer
specifically for CD and DVD and
in no way could fit other than disks in the machine.
I just wanted to point out the fact headlights are metalized, no other reason.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE
fish26
A.k.a.: benito
Fahrvergnugen
Posts: 903
Threads: 38
Registered: July 13th, 2007
Member Is Offline
Location: sydney
Theme: UltimaBB Pro Grey
Mood: Ken awesome
posted on December 27th, 2013 at 10:40 PM
An awesome job on restoring the headlights mate, you should get a massive improvement from before even if 6 volt.
bitten by the bug..........several times
psimitar
Son of Jim - Creator of Good
Posts: 2506
Threads: 148
Registered: January 1st, 2009
Member Is Offline
Location: North East Melbourne, VIC
Theme: UltimaBB Psyche Blue
posted on December 27th, 2013 at 10:43 PM
chrome and 12v conversion for P45t bulbs of std or increased LUX output or even a HID conversion will give planty of nitghtime light.
I've glued ali foil to inside of mine and boy are they bright with std halogen P45t bulbs on 12v
madness is in the eye of the beholder
matberry
Super Moderator
Go hard or go home
Posts: 8114
Threads: 134
Registered: March 7th, 2006
Member Is Offline
Location: Cooroy Qld
Theme: UltimaBB Pro Blue
Mood: enjoying waving at all my Kombi buddies from my T3
posted on December 27th, 2013 at 11:54 PM
Nice job, that's for sure.
I'm lucky, my old reflectors are hanging in there and with 100W QH they work fantasticly, and on country roads where I live or on 1000+km road trips
This nice OG German lense unfortunately got disposed of as it got a stone through it
Error
Sorry, you must be a registered user in order to download attachments.
Error
Sorry, you must be a registered user in order to download attachments.
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
hellbugged
A.k.a.: Daimo Pell
23 Windows of Awesome
48's and straight cuts
Posts: 5080
Threads: 116
Registered: April 17th, 2003
Member Is Offline
Location: Nambucca Valley NSW
Theme: UltimaBB Psyche Blue
Mood: Couldn't care less
posted on December 28th, 2013 at 06:44 AM
Great job on the lights
Thanx for sharing
HappyDaze
A.k.a.: Greg Mackie
Son of Jim - Creator of Good
Superannuated
Posts: 2887
Threads: 141
Registered: June 13th, 2009
Member Is Offline
Location: Southern Highlands NSW
Theme: UltimaBB Pro Blue ( Default )
Mood: Happy enough
posted on December 28th, 2013 at 07:19 AM
Norman, if you haven't already done so, you could fit relays - and heavier gauge wiring. The voltage drop with the standard wires, and 'big'
globes, on a 6v system is horrible. Just touch the wires while the lights are on high-beam, and you will know where a lot of the power is going.
You only need to use heavier wiring from the relays to the lights and power from the battery, and don't forget the earth wire. The stock wiring and
switches are fine for the relay coils. Mount relays as close to the lights as possible.
I'd rather wear a Beetle out by racing it than by polishing it!
65standard
Officially Full-On Dubber
Posts: 373
Threads: 47
Registered: April 18th, 2009
Member Is Offline
Location: Sydney, NSW
Theme: UltimaBB Pro Blue
Mood: Only when I'm in it.
posted on December 28th, 2013 at 08:44 AM
Quote:
This nice OG German lense unfortunately got disposed of as it got a stone through it
Mat, that's why I invested in a $50 pair of leadlight mesh protectors couple of years ago. 25,000km's on road trips and going against road trains in
the outback, and not a problem with lenses being cracked or trashed, although keeping the bug on the road from the wake of the trucks was another
thing.
Quote:
Norman, if you haven't already done so, you could fit relays - and heavier gauge wiring.
Greg, I had thought about it, but haven't done so. I do have some old 6V relays (that still work) as I was going to do it, but for my general
purpose, clean headlight lenses and reflectors, lights aimed correctly and clean contacts work fine.
Thanks for the input guys. I for one love hearing others input and experiences, as it can only add to my little knowledge base.
Any other ideas? I'm all ears.
[size=4]If it ain't broke, fix it till it is![/size]
