I am struggling to get the headlight buckets finished up. I'm right at the end but the retaining rings will not fit flush against the bucket on either one. Are there any tricks to getting these to fit right?
I installed the gaskets in the grooves on the reflectors and have clipped the lenses to the retaining rings. When I go to put it all together, it doesn't seem to fit right.
Possibly the gasket is too thick or the retainer clip on the outer ring is missing or distorted. The bucket has a slot that the clip slips into and in the photos above it appears the clip is not seated or perhaps missing altogether. With new gaskets they are difficult to compress into,place so a second set of hands could help.
Yea, the clip on this ring in the picture is still there but it keeps bending. The other headlight ring clip is broken and I'm in the process of making a new one from scratch. It definitely is a tight fit!
My experience with many new “reproduction” gaskets and seals is that they are often not the exact same size as the originals. It would not surprise me if you are fighting a combination of a larger gasket made of possibly a stiffer material.
I have found that a light cost of Vaseline often helps with the assembly process. I use that rather than any grease or oil because it is much less detrimental to materials and the excess cleans off easily.
gasket thickness plays a role, also the band (at least on 29) can NOT be tightened until it is installed and seated, and it goes around the lens, gasket, and then the bucket. i set the tab in first (typically on the bottom, and seat it in the bucket, then hold it there with one hand then put other hand on top and gently push it in place. sometimes you may have to walk the ring around from bottom to top on each side as sometimes the ring is trying to slide inside the bucket vs the outside, do not let go of the bottom. may have to loosen the ring some till it slips around and snaps into place then gently tighten it up.
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