4. The line is far from perfect, as seen by the giant gap between the cut line and the housing. Let the fit determine where to remove material for a tight fit.

5. Don't commit early on to a specific location; the looks change as the headlight sinks. Subtle tweaks like pushing the light forward, as seen here, make a big difference.

6. As indicated earlier the fit determines where to trim the cut line. Make the parts fit as tight as possible to minimize or even eliminate machine work down the line. The acute angle makes those jobs tedious.

7. Schmidt wrapped the housing with paper and taped around the cut line to make a template. He inverted the template when he laid it on the other housing. He cut the new hole short of the line and enlarged it to fit the fender.

8. After trimming the bucket to fit Schmidt taped the headlight and King Bee rim in place to verify the look. At this point L-shaped tabs tacked to the fenders locate the bucket but Schmidt later tacked tabs tacked to the buckets and held them to the fender with temporary panel fasteners.

9. Schmidt then cut the front off the Anglia bucket at a point where the diameter matched a similar point on the King Bee bucket. Then he tacked the King Bee flange to the Anglia bucket. Note the L-shaped brackets from the previous step.

10. The housing rim determines the headlight location, which determines its aim. Schmidt cut a disc to fit against the mounting lip and welded bar stock to it perpendicularly. Then he tuned the opening to aim the lamp using a level, among other things.

11. Then he aimed the lamps horizontally. He established a centerline down the length of the car and then created a perpendicular line to it. All measurements refer to those lines. It takes a lit lamp for final aiming but this will get things very close.

12. He backed up his data with other measurements, in this case the dimension from the A-pillars to the headlights. This improves visual consistency but leveling the beams with protractors on the rods welded to the discs offers the precision that makes it possible to later fine-aim the lights by thin shims.

13. Comfortable with the location Schmidt welded the buckets to the fenders. Working from the inside minimizes the weld bead's prominence on the outside. That in turn translates to a very small radius.

14. Schmidt finished by mounting the headlights. A thin layer of lead will create a softer transition. With the fabrication part done all that remains is to shim the headlights within the buckets.

SOURCE
Steve's Auto Restorations
503-665-2222
http://www.stevesautorestoration
s.com