Date:         Fri, 1 Nov 2002 13:37:04 -0800
Reply-To:     pensioner <al_knoll@PACBELL.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         pensioner <al_knoll@PACBELL.NET>
Subject:      Re: Rectangle headlight conversion to common 200mm headlights
In-Reply-To:  <200211011947.gA1JlFuE631160@vm2-ext.prodigy.net>
Content-type: text/plain; charset=iso-8859-1

FWIW various formulations of "Silicone Seal" or Room Temperature Vulcanizing
rubber can handle rather large extremes of temperature.  As long as the
surfaces are very clean, 212F temperatures won't degrade the material enough
to allow it to separate.  The only problem is the second rock.  Then it's
pretty obvious that you'll need a third headlight unit into which you mount
the third 200mm Cibie you carry as a spare.  Works but...a bit messy for
repairs.  I suspect a standard DOT holder from a Cherokee, or Ford Exploder
could be adapted to the existing VW frame.  My best results came from using
the pre 85 7" grille and some standard 7" H4 headlights.  Plenty of light,
nice pattern, easily changeable.  Distinctive.

If you worship your vanagon as a religious icon, it might be worth the
trouble.  If you just want to see better at night, other alternatives seem
much simpler.

Cibie Z-beam replicas are ~35usd.  A used grille and buckets ~50usd.  A
homemade relay harness ~20usd.  So for around a hundred frawgskins you have
very acceptable lighting.  The major problem is high to low filament
placement so the cutoff is correct and the high beams don't jacklight owls.
This has been discussed before of course.  No really good solution if your
centerline for headlights is much above a standard cars lights.  Same
problem with the 200mm units. The ideal is the independently adjustable
Marchal Ampilux dual H1 units.  You can have your cutoff and place the
highbeam hotspot where you want it.  Alas, these are quite dear.  The last
new set I recall sold for ~400USD for 20year old NOS headlights.

An alternative is the Cibie Biode or the dual filament Oscars mounted at
bumper level and controlled as auxiliary lights.  These too fetch a fine
price.  A used set usually goes for around 200usd.

A company in Brasil (sic) markets an H4 + H1 unit that is a direct fit into
the older bus and bug holders.  I can forward information about these.