2G headlight bucket conversion questions.

[Bloodlust182]

Hey guys, Im swapping in some 2G headlight buckets and keeping my 1G bumper and I have a few questions.

1. What kind of cutter should I use to cut the buckets from my car. I used a regular drill bit to remove the 2G buckets from the donor car, but I cant do that to my car as there would be nothing to weld the buckets to on my car.

2. Any tips on welding the buckets in? Im planning on tacking about 4 or 6 spots before I start going at it. Being that the metal is so thin, what setting should my welder be on (eastwood mig)? Im guessing a little bit lower on the amperage?

3.Wiring up the 2G headlights is pretty simple on the headlight end. On 1G cars the high and low beam are not on at the same time, and are not wired to be. IIRC the 2G headlights both are on when the highs are on. How do I go about wiring them both to be on with a 1G harness? Im guessing a jumper wire on a relay would work, but If there is a better way I am all for it.

[Chris@Rvengeperformance]

1) Spotweld cutter would be easiest
2)Use .023 wire (hopefully not flux core). Experiment on some scrap of equal thickness. It is easy to measure. Dial your settings in from there until you have a decent weld with good penetration and no blow through. Settings may need to be a little hotter than normal due to the short length of time you are striking an arc.
3)I think brian had a post on this on the other site. My old car was converted already, so I can't remember how this works, but I think they were just jumpered together. I was not really completely satisfied with that arrangement either. You gotta be careful wiring it up or you will blow that bigass 40 amp fuse and the thing is like $7

[Bloodlust182]

Im using my neighbor's welder. I used it to weld in my AWD frame mounts with shield gas, but it is all out now. Ive gotta look into getting it filled tomorrow and see how much it costs. It is a relatively small bottle, but im not sure on it's size.

[Chris@Rvengeperformance]

well whatever they quote you to fill it, try to negotiate. They try to get me for $60 for a little 40 cuft tank, but if I tell them that's too much all of a sudden it is $30.00. They have HUGE flexibility in what they can charge you.

I wouldn't use flux core if you want the welds to be pretty and it will throw a lot of splatter around, so it will be hard keeping the rest of the car safe.

[Chris@Rvengeperformance]

oh I got one of these for on the car jobs:

Amazon.com: Hobart 770635 Heat-Treated Fiberglass Welding Blanket, 4-Foot by 6-Foot: Home Improvement

It is not bulletproof, but it helps.

[Bloodlust182]

Im pulling off my bumper and fenders to do the whole thing so I should be easily able to grind away and splatter/ deposits. Airgas just quoted me $27.30 to fill a 20 Cuft tank. Doesn't seem too bad to me, but I've never had a tank filled haha. Ill likely split the cost with my neighbor anyway. Going to fill the tank tomorrow before work. Going to get this project rolling by Friday. Got a link to that wire-up btw?

[mb3000]

Not really much to it. Just use this:




And drill out all of the same holes. Do one bucket at a time, and then take a cross measurement from something like the strut bolt to a common mount (radiator support bolts) and make sure they line up together vs. the other bucket which you just left alone. Tack it on and re-measure then weld it up.

Unfortunately I don't have any pictures, but like mentioned above Brian does somewhere I'm sure.

[Bloodlust182]

I really need to grab a few of those haha. Found the headlight wiring diagram Brian made

[mb3000]

I think you could do all of it with one if you get a quality tool and use good cutting lube. I replaced my radiator support and I didn't even have to flip it over and use the other side.

[stealthee]

LOL, I made that diagram in paint like 10 years ago. My typo is still there.

If the diagram doesn't make any sense to you I can try to help explain it better. The main thing I can offer is make sure your separate ground is sufficient. A frind of mine 2G converted his car and said his wiring starting sparking when he was testing. Found out after calling me and me walking him through it that his ground sucked. As soon as he fixed that it was good to go.