Brain Storm Low Profile Headlight Installation

(part 3)

18. Here is what the assembled bucket now looks like with all 6 screws in.

19. Add nyloc nuts to the part of the screws that are sticking out the back of the bucket.

Only tighten them until they are flush with the bolt end. Their only purpose is to keep the screws from being adjusted all the way out.

20. Now mount the relay to the inside front middle of the bucket.

Be sure to put it sideways so that none of the wires will touch the lamps. They get very hot and will melt the wires if they touch.

21. Connect the wires like this.

Black to black, relay white to low beam white, relay orange to high beam white. (In case you didn't know, the lamp that will be closest to the outside fender of the car is supposed to be your low beam.)

22. Install the pivot to the rear of the bucket.

Notice that the nut is on the opposite side as the square hole? Yup. I got this one to mount backwards the first time too.

23. Remove the rubber bumpstop bolt from the old bucket assembly.

BSP recommends that you pull the rubber off the bolt to get at the hex head under it. I used a flat blade screwdriver with the slot on the other end of the bolt.

Just be careful. The bold is kind of soft and won't take much abuse.

24. Install the rubber bumpstop bolt on the new bucket.

Make sure that you have it installed the right direction. The rubber part sort of faces away from the pivot bolt. The previous couple of pics are wrong. Here is how it's gonna look.

25. Now gently tap or press the old brass bushings into the holes on the new bucket.

I ended up using a vise to press it in and could not get it to seat all the way.

Not a problem. It works fine when done.

26. Remove the stock pivot arm from the retractor motor. It's a bit hard to get to. I used a box end wrench.

Here is what it looks like with the pivot arm removed.

And here it is again from the front.

Continued...