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Special Coupe Frank · 06-30-2012, 03:35 PM

Went through this myself with repro stuff... focus screws were too long (by at least 1/2" ), and the bayonet quick-connect at the bottom of the headlight shell were always giving trouble: either shorting-out or losing contact.

Part of the problem was the modern "soft" thermoplastic insulator bushing, the other was poorly-formed / fitted metal parts.

I soldered Bratton's blunt-end bullet terms on the ends of the harness wires and the socket wires, and joined them inside the headlight shell with female bullet connectors, and rigged an insulating "bushing" from a piece of rubber hose to get through the repro bayonet fitting at the base of the headlights, thus being able to use the stock conduits.

That was over a year ago, and since then, no blown fuses or blown headlight bulbs ( and I drive with my lights on day or night )...

Someday I hope to have real Ford headlights and stock connectors or A&L repros... in the meantime, this is working for my driver A .

06-30-2012, 03:35 PM	#7
Special Coupe Frank Senior Member Join Date: May 2010 Location: Northeast Penna Posts: 2,108	Re: Fuse Blows with Headlights On Went through this myself with repro stuff... focus screws were too long (by at least 1/2" ), and the bayonet quick-connect at the bottom of the headlight shell were always giving trouble: either shorting-out or losing contact. Part of the problem was the modern "soft" thermoplastic insulator bushing, the other was poorly-formed / fitted metal parts. I soldered Bratton's blunt-end bullet terms on the ends of the harness wires and the socket wires, and joined them inside the headlight shell with female bullet connectors, and rigged an insulating "bushing" from a piece of rubber hose to get through the repro bayonet fitting at the base of the headlights, thus being able to use the stock conduits. That was over a year ago, and since then, no blown fuses or blown headlight bulbs ( and I drive with my lights on day or night )... Someday I hope to have real Ford headlights and stock connectors or A&L repros... in the meantime, this is working for my driver A .