Headlight Bucket

The headlight buckets needed straightening, stripping, and repainting. In addition some jigs were made to make sure that the 2 sides matched. The passenger side appeared to have been in an accident and it was mis-shaped.

I made 2 jigs. The first were to hold the buckets and the surfaces for the mount were taken from a 3D scan. This did not turn out perfect but it was close enough to compare the two sides to each other. I made a new jig based on a 3D scan of the car side and found that the 3 mounts don't actually line up. The outside mount is being bent when the screw is put it. The car side needs to expand. The mount must bend out a little to get the bold in! This picture show how the right pin does not line up. It is about 1/2 bolt diameter off. The picture is off vertically but it really is only a horizontal issue. I have a second jig that goes into the car side and the pin fits the car but not the bucket. This is how I found that the 2 are different. This forcing of the mount in the car is same for both sides.

I aligned the headlight bucket scan and the scan of the surrounding area and this demonstrates the issue. The bucket was moved to best fit the cars mounts. It is slightly rotated. If matching up the 2 inner mounts then the outer one is off by about 10mm at a diagonal!