Fitting headlamps behind the fenders

NikosF · #1 (**permalink**) 08-07-2003, 10:06 AM

I want to change my US-spec '67 Duetto to the EU-spec headlights, by installing Cibie H4s (I know they should be Carello H4s) to replace the pathetic sealed beam units, moving them behind the fenders and covering up with Carello covers.

I understand how to fit the actual Carello covers and what mounting harware to use - but not sure about the headlights.

Has anyone done this that can give me the 'Dummy's guide' version of what to do. Specifically what do I need in order to move the headlamps to mount from behind the fender instead of the front.

I take it I unscrew the assembly from the front, open up the little round cover in the wheel well (which appears to be attached with a phillips screw that hasn't been moved for 36 years and I'll probably battle to get off). Then what? What mounting hardware do I need (screws, bolts, etc)? How much of a PITA is it?

I just want to get a good sense before opening everything up and then having to make multiple runs to the hardware store.

Thanks,

meatpile · #2 (**permalink**) 08-07-2003, 10:30 AM

Good luck, I know it looks better.

**John M** · #3 (**permalink**) 08-07-2003, 12:13 PM

Hey Nick:

I have done this conversion on my 78 and if its the same on the duetto, here it goes.

You may want to save this project until you are getting some body work done. Its a very simple conversion, but you will need to paint to make it complete.

1. Pull the headlight housing from its outside the fender position.
2. Fill the old mounting holes for the headlight bucket. Leave the adjustment rectangles at the noon and 9 o'clock position in place
3. Fit cover to mark cuts. Cut new rectangular holes (if not aready there) for headlight perplex cover's tabs. Drill hole for cover's mounting bolt and nut.
4. Prep and Paint....All this new area behind where the old headlight bucket sat will now be exposed to the world.
5. Remove inner fender well access panel. 2 screws
6. Install new outer chrome trim ring that comes with the kit. Old style trim ring is not used so sell them on ebay.
6. Inside the fender you will find 3 studs for mounting the bucket. One at the 6, 10 and 2 o'clock positions. Your bucket already has holes for these studs. After you have installed your headlight with bulb into the bucket and plugged it in, simply slide the bucket on and secure with three 6mm nuts (you need to check the size on these as I am not sure, but they are small). Be sure to attach your harness ground wire somewhere like one of those studs.
7. Close fenderwell access panel
8. Put plastic boots in the cutouts for the perplex covers.
9. Slide covers on, with the perplex cover's tabs sliding into the plastic boots.
10. Put the bolt through the perplex cover's nose and secure from underneath. Don't overtighten.

Thats it.

Best of luck,
John M

NikosF · #4 (**permalink**) 08-07-2003, 01:44 PM

Thank you John,

Excellent!

That's exactly what I was looking for. I've got my Carello covers already, and I'm just waiting for my new Cibie H4s and relays then I'll give it a try.

Looking forward to better light AND lookin' good.

Alfapaulic · #5 (**permalink**) 08-07-2003, 10:05 PM

This will be a worthwhile endeavor...looks and lights.

meatpile · #6 (**permalink**) 08-08-2003, 07:32 AM

Here's a pic of mine up close....

**John M** · #7 (**permalink**) 08-08-2003, 09:52 AM

Hey Meatpile:

Very nice job. Thats how they should look. You are missing the inner chrome trim ring. If you want to source them, I got mine from OKP.

Best Regards,
John M

NikosF · #8 (**permalink**) 08-08-2003, 10:21 AM

Meatpile - those look good.

Another source for the trim rings is Highwood Alfa which is based in the U.K. They have the rings for £5 (about $8) each.

If anyone is looking to do this conversion Highwood sell the pair of Carello covers for £74 ($118). The trim (screws, rubber plugs and trim rings) adds another $30 or so - still a lot cheaper than the US sources. And I ordered them on a Thursday and had them delivered in Boston by Monday.

meatpile · #9 (**permalink**) 08-08-2003, 11:58 AM

What do they look like with the chrome trim ring?

**John M** · #10 (**permalink**) 08-08-2003, 02:05 PM

Here is a pic of someone's car at the convention with the trim ring in question:

Best Regards,
John M

Alfapaulic · #11 (**permalink**) 08-08-2003, 10:06 PM

Let me know Nikos F how your light conversion turns out & quality of the parts etc.

Thanks

alfacupp · #12 (**permalink**) 08-09-2003, 12:33 AM

Does anyone have some old carello cover that are glazed over ect. I am looking for a pair to be painted. I got out bid on ebay a few weeks back on some. If you have some for sell please let me know. Thanks alfacupp

NikosF · #13 (**permalink**) 11-16-2003, 07:05 PM

Thanks for all the input.

Thought I would post a picture of how they came out.

I bought the covers and trim ring from highwoodalfa in the UK. Covers were genuine Carellos (in Alfa bag). Fit perfectly. And much cheaper than US suppliers.

Moving headlight buckets behind the wells was more difficult. Bits of the bucket had to be ground away to make them fit. All is well now, and the upgrade to Cibie lenses and H4 bulbs (Philips Visionplus) has made an enormous difference to night-time visibility.

**John M** · #14 (**permalink**) 11-16-2003, 09:34 PM

Perfect Nick. They look great.

Best Regards,
John M

Farace · #15 (**permalink**) 11-17-2003, 09:02 AM

I can only hope mine look half that good. Waiting for the parts to arrive from Germany (Hurtienne). I'm not going to install the covers until spring, after the car passes inspection, though. I don't know what DMV would say about them, and I don't really care to find out, so I'll just avoid the issue.