Refreshing euro smilies...How to put back together.

[CMG]

I have a couple pair of euro headlights I'm refreshing and can't figure out how to put back together. The part I am having trouble with is the three little black plastic pieces on each light that the adjuster end pops into. I've tried putting them in then putting adjusters into them and also first putting them on adjuster ends and trying to pop into headlight holes. I don't want to break something how do I do it?

[ST1G]

I have a couple pair of euro headlights I'm refreshing and can't figure out how to put back together. The part I am having trouble with is the three little black plastic pieces on each light that the adjuster end pops into. I've tried putting them in then putting adjusters into them and also first putting them on adjuster ends and trying to pop into headlight holes. I don't want to break something how do I do it?

What I did was used channel locks to pop them in. They do require some pressure to pop in there. I put the socket into the hole (not all the way in). then put the adjuster ball in there, then put the ball into the socket. The socket usually is pushed into the headlight at that point.

[CMG]

Ok so line it all up then pop into place. I'll give that a shot

[CMG]

Holy crap that is a pita. I still can't figure it out and truing not to force it. I'm putting together a set of the helix smoke crosshsir headlights with matching smoke tails and sidemarkers. Gonna have that set plus my stock set plus bosch euro smilies w/ startecs for 3 lighting options.

[Steve Corbett]

It's been a bit since I did mine but I do remember, Holy crap! somethings going to break. It goes a lot easier if you put the plastic cup on the adjuster stud then install into the housing.

[NameIsStanley]

It's been a bit since I did mine but I do remember, Holy crap! somethings going to break. It goes a lot easier if you put the plastic cup on the adjuster stud then install into the housing.

I just finished refreshing my headlights and that's how I re-installed the plastic cups and adjusters. Don't worry, you won't break anything.

[CMG]

Got em all together, i'll post pics of the final product soon. I only replaced the adjuster studs that were broken and used all new cups. It's over $100 if u were to use all new parts. Anyways, i put all the adjusters in place, with the cups on. Then i used pluers to squeeze the cups to loosen then up. I hit all three cups with a heat gun then put light in place and squeezed them until all three popoed on. I seriously was afraid the headlight would break and i would cut myself up i was putting so much pressure on it. It helps to remove trim rings and do not lay on a surface and try to push in you can bend stuff, squeeze in your hands.

[CMG]

So here's how it looks with adjusters and cups installed and gettin heated up



Here's the finished product



I'm actually not gonna be using crosshairs right now gonna use bosch smilies for



Also have a bunch of oem connectors gonna make plug and play wiring adapters

[CMG]

Btw i have the hella highs and lows i removed to uses the bases and i am selling those

[AndrewBird]

FYI, multiple plugs/connectors on a high draw wire like headlights creates a lot of heat and can cause a fire. You are better off hard wiring them. This eliminates a potential point of failure.

I highly recommend getting some lamin-x for protection. Would set to crack a lens due to a rock. I bought the thicker stuff they sell, but wish I would have gone thinner. It's thick enough you can see the edge of it and I think it takes away from the look of the lights.

[CMG]

if you are talking about the use of terminals for the adapters increasing resistance you are mistaken. That's why i am using oem and new parts to eliminate any resistance issues. Hard wiring it would have more potential for increased resistance at the soldering point. And also, if you own an e30 m3 you would never hack up anything on the car, period.