Headlights Switch Relocation

 I relocated my Headlights and Parking Lights switch onto that piece of Dash Trim that fit along the lower part of the stock OEM dash just below where the Gauge Cluster used to be. I had to do some cotton and modifying of the plastic part to make it fit into the space with my wire looms but got it to eventually fit in there nicely again. The next step was to make an aluminum bezel to fit over the Headlights switch. I cut out a piece of aluminum and cut out a hole the same size and shape of the hole that was in the stock OEM bezel that held both the Headlights and Dash illumination dimmer switches. I sanded it down (top left) and then marked where I would need to bend it (top right). If you have a "Metal Break" bending the aluminum is easy if not you can do what I did and use a Vice and a hammer.

I then cut out a hole in the plastic dash trim (left) big enough for the Headlights Switch and then fit the switch into place (right). I put the plug back on the end and test fit the whole thing back into the dash. I had to use my Dremel to do a little cutting in the stock OEM dash to make the plug fit into the space better because it's a big fat beast of a plug but with a little cutting work it can be made to fit nicely to the hole. I fed the wires from the plug in through the hole and down in through the underside of the dash, that way I can solder them the the other wires I have going into the wires that came out of the area of the stock OEM dash that the original plug was attached too. Basically all I am doing is extending the wires and relocating the switch to somewhere more convenient.

After bending the aluminum bezel into the right shape I fit it into place over the Headlights switch (left) and drilled in four holes to screw it onto the dash trim with. Next I sanded down the aluminum bezel one last time before giving it a good cleaning before painting it (right).

Once the paint was dry after baking in the hot sun for a few hours (left) I then attached the bezel to the plastic trim with four small black screws (right). With that job finally done the last thing to do was to attach the whole assembly onto the stock OEM dash and give the Headlights a test, something I was pretty sure I had never done since the car arrived almost two years ago. WOW! two years ago!! It's sometimes so surreal thinking about that, the time has gone by so fast and so much has been done on my K.I.T.T. Project.

Here is the final assembly in place, it's not screwed in yet as I have a lot more mucking about to do with wiring and such but it's in place and has been tested out, check out the two videos in my previous postings to see how that turned out. ;)

Headlight Assemblies Back In

Now that the paint is dry and has had time to cure overnight it was time to put my motorized headlight assemblies back into the front of the car. For right now they are just bolted back in finger tight so I can do any adjustments to them once my Turbo Hood, and front nose are installed onto the car. Once that is all done I'll replace the headlight bulbs and bezels. The bezels I still need to perhaps trim but I'm not there yet, gotta see how things are fitting first.

Headlight bays painted

Finally got around to priming and painting the headlight bays. I gave the whole area a good going over with my drill using a wire brush tip to scuff up the painting surface real good before priming. Cleaned up the surface with some rubbing alcohol and a quick going over with the tac cloth just to catch any particles of dust that might be still there. So now I'll be able to reinstall my motorized headlight assemblies. I won't put the headlights or the bezels in just yet as it will make it difficult putting the front nose on and I still need good access to those areas where the bolts attach the front nose to the fenders. I'll also probably need to still run some wires for either my existing turn signals or some after market turn signals so even though I'm anxious to get my headlamps up and running again for now I'll make do with the headlamp motorized assemblies back in place, putting the bulbs and bezels back in will be no biggie later on. 

While I was painting I decided to give the front nose support plate another coat of paint too after giving it a good cleaning with some rubbing alcohol.