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7 Inch Headlamp Conversion

7" Headlamp Installation

Alex Cannara


There seems to be no lack of confusion regarding the procedure to convert a U.S.A XJ to the 'proper' 7 inch outer headlamps.  Alex Cannara was kind enough to document the process in pictures.  Click any picture for a larger view.

old lamp

1)  Old lamp with trim ring removed.  Retain clip nuts and screws.

cutting out old lamp wiring

2)   Remove bucket and cut wiring close to where it enters the bucket.

prepare old wires

3)  Tin the cut wires with solder and prepare shrink tubing.
 
preparing new bucket

4)  On 7 inch bucket, cut wiring, leaving a reasonable length.  If new bucket has a provision for a 'city light', do not cut that wire.
 
sealing bucket

5)  Use Liquid Tape and shrink tubing at wiring grommet to ensure a good seal against water.  Start placing spiral wrap on wires.  Liquid Tape (or tool dip) available at hardware stores or Harbor Freight.  Spiral wrap from Radio Shack.

soldering

6)  Lap solder the wiring joints, and heat shrink the tubing.
 
dressing wire

7)  Use Liquid Tape and tie wraps to seal existing sheath the spiral wrap.  Note red 'city light' wire bundled out of the way, available for future hookup.
 
fitting trim ring

8)  Fitting the trim ring.
 
lamp used

9)  Lamps from J.C. Whitney used with 100/55W H4 bulbs.  If you're using H4 lamps like this, it's a good idea to clean them first.  If you remove the H4 bulb, you can look into the lamp shell and see if there's any trace of fogging, due to oily manufacturing residue.  It may take sunlight to notice this.  In any case, you can take a clean sock, a wooden stirring spoon (don't tell your wife) and some acetone -- soak the sock's end in the acetone and use the handle of the wooden spoon to work it into the bulb hole and all around the inside of the glass and reflector.  You may not get at all spots, but one or two shots of this should get a very clean lamp shell.  Before putting the bulb back in, clean it with acetone too.  The idea, beyond removing any fogging, is that organics and quartz don't go together well at high temps, and halogen bulb life can be dramatically shortened, even by fingerprints.
 
half done

10)  One side done, one side not, showing the dramatic difference.
 
finished

11)  All done!




 

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