Date:         Sun, 21 Aug 2011 23:24:21 -0500
Reply-To:     John Rodgers <inua@CHARTER.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         John Rodgers <inua@CHARTER.NET>
Subject:      Mounting SA Grille Inner Lights
Content-Type: text/plain; charset=ISO-8859-1; format=flowed

  I have finally gotten around to installing the VW South African grille
on my van. When attempting to install the lights, I found the the
alignment issue to be a royal PITA!.

On my van, I needed to drill new holes for the inner light mounts, since
the old ones didn't match. To position the lights, they have to be put
in place, then the grille installed, the lights positioned, then the
lights held in position and the grille removed. Then the new holes
drilled. I've got news! Holding the lights so they don't move while
screwing around with that grille is almost if not outright impossible.
The light would move slightly every time, and then would be wonky inside
the grille when the grille was again mounted. I had to find a way around
this.

The solution:
I set the lights in as near the correct position as possible, then
drilled one upper hole and one lower hole diagonally opposite. Next, I
dismounted the light, and drilled the holes in the mount that were
diagonally opposite to match those just drilled in the body. I then
remounted the lights. I installed a screw in each enlarged hole, and
snugged it down just ever so slightly. This put pressure on the mount so
it would not move, yet not so tight that I could NOT move it. The
enlarged holes allowed me to move the light mount left and right, up and
down just a little bit. I then mounted the grille, and with modest
finger pressure, positioned the light exactly in the center of the
grille light opening. The enlarged holes allowed me to do this. I
removed the grille, and the lights stayed put. I just tightened the
screws, then  added the other two, and was done.

This method was far easier than anything I saw described elsewhere, and
the fact that two screws are through slightly larger holes in the light
mount matters not a whit. One can always throw in an extra screw here or
there if needed.

Hope this helps someone else trying to mount the SA Grille Inner Lights.

John

--
John Rodgers
Clayartist and Moldmaker
88'GL VW Bus Driver
Chelsea, AL
Http://www.moldhaus.com