Marchal headlight installation, need help.

[Daniel Lorenz]

I have a set of marchal 61243603 headlights as seen in pictures. Tried making my own solution to avoid having adjustment screws visible thru the light covers.
But I am loosing faith in the solution I made up since the plastic holders just cant handle any decent spring pressure to hold the headlights steady from vibrations.

How is aftermarket headlights installed in most kits? (Picture please)
And how does the Marchal Original solution look like? Can only find frame for the 61343303 headlights

Same question applies for front spots, they are in a very early stage and have not manufactured any mounts yet. Just aluminium frame as in picture.

Are there any good universal adjusting screws that can be mounted from the rear that has a pivot point and allow spring loading? That would probably solve my problem för both headlight and spots.

 

[Lee Patterson]

The original Marchal mounted to a flat plate that is bonded to the inner body. The 3 holes are necessary to adjust the light both up/down and r/l. How would you adjust the light otherwise with the body on the car? In the picture below, the plastic piece is threaded and rivets to the mounting plate. The back side plastic knurled nut holds the light in place. There are 3 of them. Adjustment is made from the front as the threaded rod has a slot in the end for a screw driver.

 

[Doc Watson]

 

[Daniel Lorenz]

Looks interesting. Are there any pics on the installation of the frame and adjustment screws?

 

[Doc Watson]

Sorry haven't got that far yet...

 

[HILLY]

Some of the components.
The frames in Doc's photo are glassed into the bodywork.

 

[murf]

Are the brackets above glued to the headlights,also are they avaliable with the plastic adjusters.cheers shaun

 

[HILLY]

The brackets are spot welded to the headlight casing.
Obviously the lense is removed and repainting or atleast touchups are required.
We made our own brackets and plastic fittings.

 

[Pedro]

Hi Peter, how hard was it to remove the lenses? what was the process?

 

[HILLY]

Hi Pedro,
It is a bit of a mission.
I flattened the small retaining lip on the casing with a pin punch and then used a thin blade to steadily slice through the sealant between the lens to the casing.
Once the brackets were fitted I cut out a 6mm plate steel template slightly larger than the lens to reform and reinstate the retaining lip. Then its just a matter of repainting the casing and refitting the lenses.

 

[Pedro]

Thanks Peter good information.

 

[murf]

Are the bracket sets adjustment screws being sold as a set.can I ask

 

[HILLY]

Definitely do not have any screws or plastic knobs left but can check if I have a complete set brackets and possibly the white plastic nut plates that are riveted onto the alloy bracket in Doc's photo.

 

[Daniel Lorenz]

Really interesting information you have shared with us. For my part though it looks like alot of re-work and finding hard to find parts.

I had a chat with a local Volvo enthusiast that informed me that there is a upgraded version of the adjustment nut.(plastic)
I took two with me home for test and it sure is tight since it was made for m6 screw and not 1/4-28 as my current screws are. There is also alot more material to work with if I need to thread them with inserts at a later stage.