jabingb wrote:P.S. Would still like to understand how your Perspex head light covers are secured?
The perspex head light covers are held on with screws through the Perspex and fixed to three tabs:
.
With tabs below, prior to drilling Perspex and screws
With screws:
Headlight buckets were fabricated from aluminum. This was done retaining the original headlight bobbins to allow one to revert to the original headlight pods later, if so desired. So, no permanent change to the body. Pods and mechanisms all retained (all of which BTW were in perfect working order - including vacuum activation).
To these buckets, three angle tabs were riveted to accept the screws through the Perspex. Screws incorporated small rubber o-rings to cushion against the Perspex. The buckets and tabs were then painted body color. Since this is a dark BRG, the tabs are not particularly visible.
It should be noted that drilling the holes in the Perspex has to be done very carefully. It is easy to crack these especially since you are drilling close to an edge. In addition, not all Perspex covers are the same. I found them to vary as to shape and thickness. They may have to be trimmed to align with the headlight hole in the body. I did find some that were too small to fit the S4 body - could have been original 26R - thicker as well.