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Old 11-07-2011, 01:42 PM   #81
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I've started cutting the backs of mine out, should have one finished tomorrow, you've got to cut quite a bit out.... getting it straight then putting the bolts in is going to be the hardest bit for me I think.
I'll put up some pics tomorrow of how I cut mine
Did u find some bolts? and grab a mate to give u a hand and.pay him with beer thats what im gunna do
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Old 11-07-2011, 01:45 PM   #82
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Just thought id mention what i thought would make lining it up easier, hold it in place with one hand and hot glue it in place temporarily while you mark out all the holes, just my 2c....
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Old 11-07-2011, 02:43 PM   #83
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Only pay him after its finished, otherwise the accuracy may go out the window lol
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Old 11-07-2011, 03:47 PM   #84
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Yeah found some bolts just using 4mm x 50mm bolts and I'll cut the ends off once I'm done
Got Dad to give me a hand It's not too hard to do really, just spent a lot of time on the first one not wanting to dremel too much away. I held it in position and Dad put some tape across the back to hold it there. Marked where the bolts have to go and just drilled the holes. Put it back together and it works well. Probably spent about 5 hours all up on the first one and about 2 on the second one. Now I've got to sand back all the chrome and paint everything. I'm not going to glue or silicone anything as the plastic of the headlight is more than strong enough and some nylox nuts will stop it coming loose from the vibrations
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Old 11-07-2011, 04:43 PM   #85
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Yeah found some bolts just using 4mm x 50mm bolts and I'll cut the ends off once I'm done
Got Dad to give me a hand It's not too hard to do really, just spent a lot of time on the first one not wanting to dremel too much away. I held it in position and Dad put some tape across the back to hold it there. Marked where the bolts have to go and just drilled the holes. Put it back together and it works well. Probably spent about 5 hours all up on the first one and about 2 on the second one. Now I've got to sand back all the chrome and paint everything. I'm not going to glue or silicone anything as the plastic of the headlight is more than strong enough and some nylox nuts will stop it coming loose from the vibrations
**** yea. wen u get a chance throw some pics up im gunna attack mine on wensday thursday. hope i can knock them over. with the shroud on can u see much of the reflector?
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Old 13-07-2011, 01:53 PM   #86
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You can't see much of the reflector but the problem is the bit you can see shows the bolts pretty clearly which isn't as neat as I'd like. Going to paint the reflector to to stop this and maybe later on make some shrouds up to cover everything that's exposed

Here's them chrome, which looks nice and OEM but I'm still going to go for black. Have to wait for a warm day to paint them first though



The back



You can see the screw in the top right of the reflector here

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Old 13-07-2011, 02:07 PM   #87
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looks bloody awesome. =]=]=]=]
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Old 13-07-2011, 07:52 PM   #88
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almost done my first one =] bit of a pain in the ass but just gotta have patience =]
hay daniel want me to throw a pic up with the black headlight so u can decide? or u set on black
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Old 13-07-2011, 11:16 PM   #89
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hay guys be very careful when putting the reflector back in the housing that the little plastic bit the adjustment screws go in. mine have been stripped =[ so now im stuck and cant use the headlight. also make sure u push the ball back in the cup =]
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Old 14-07-2011, 02:18 AM   #90
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Yeah I'd really appreciate a pic Pretty set on black housings at least as I like the contrast against silver

Damn, I'm sure you could glue a bolt or something similar back in its place to keep the adjustability though.
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Old 14-07-2011, 01:52 PM   #91
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So went bunnings to find a nut to epoxy on only to find out that no nut fits the thread of the screw :S so now im most definatly screwed
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Old 14-07-2011, 02:00 PM   #92
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Did you look at only Metric? They're probably Imperial threads being US.
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Old 14-07-2011, 02:50 PM   #93
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yer tried imperial as well cuz thats what i was thinking but nope either too big or small. a 5 mm thread bolt cam close. so now on the hunt for a broken front headlight as i dont se the need to ruin a good headlight someone can use. or somewhere to get the clip
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Old 14-07-2011, 04:07 PM   #94
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hope this helps daniel



and the tiny little plastic captive nut that is causing me heaps of trouble


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Old 14-07-2011, 04:23 PM   #95
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Looks great

Hopefully you'll find something, maybe post on mazdas247 to find out if the 1.8 headlights have those clips as they'll be 100x easier to find.

Painted all my parts today so hopefully tomorrow night I'll put everything back together and put them on the car on Saturday night.
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Old 14-07-2011, 04:26 PM   #96
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Looking good guys!

Perhaps this will motivate me to install mine
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Old 14-07-2011, 04:27 PM   #97
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yer im gunna try that =]
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Old 14-07-2011, 04:50 PM   #98
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Looking good guys!

Perhaps this will motivate me to install mine
Haha thanks Been wanting to see yours for a while now
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Old 14-07-2011, 04:56 PM   #99
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Looking good guys!

Perhaps this will motivate me to install mine
thanks cant wait to see urs with the lip i want =]=]
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Old 15-07-2011, 11:02 PM   #100
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So... I may have kind of stripped my little adjustment nut too :'(
Got one back together fine but the other one didn't line up and I stripped it trying to line it up again
If you find a spare or an alternative please let me know
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