headlights conversion nightmare (long post)

[Tin Lizzy]

SOOO embarassed that I had to share this !!
I have been working on converting my original headlights to new halogen square headlights a few hours at a time for about a week now. took out original buckets,headlights and the front skin off.
Took the original headlight buckets and squared the holes to allow the new lights to fit. test fit the headlights in the buckets and they fit well. Painted the old buckets with box liner paint and they looked great. Found a great rubber sealer to fit around new lights and it worked great.
Tonight I fired up the coach after charging the batteries for about an hour and drove it into the shop.
Left the coach running with the backend out side the door and worked for about 3 hours fitting buckets, notched out a small section under door to allow the back of the headlight bucket to fit, re-riveting them in, refitted front skin over buckets and rivetted back in place.
Stood back took some pictures and patted myself on the back several times!!! What a genius!! Only thing left to do was manufacture a filler piece to allow for curve of bus.
I Decided that it was time to go for supper and that I would come back tomorrow , manufacture the filler piece and connect wires and aim the headlights.
Jumped in the coach released the air brakes and tried to push in the clutch.....................1/2 inch of travel and then nothing. stomped on it several times with no luck and decided to take the trouble light and check it out. Everything seemed ok but why a frozen clutch??? Called my buddy Dave (MCI Cruiser) all the way in Arizona to ask his opinion. His suggestion something I did was blocking the clutch. Not a chance says Harry I didn't move anything.
Took out the hammer and beat on the clutch pedal for a while and nothing!, took the hammer and went into compartment under drivers seat and beat on the mechanism a little.....nothing.
Grabbed the clutch arm and pulled down hard and to my surprise it stopped when it hit the top of the plastic housing on the back side of the new headlights.!!!!
took out the new headlight on the drivers side and surprise the clutch works just fine......another lesson learned. Back to the drawing board and start from square one again.
Just when I was starting to think I had this mastered.
Harry

[TomC]

Sounds like old Murphy is at work again.  One of the things that kept me going when things went wrong was to repeat several times to myself "it's Murphy's law".  Good Luck, TomC

[dreamweaver]

Harry, they don't look bad at all. As I said in our phone conversation it had to be something stupid. Glad you found the proublem. I should put mine in soon, I'll
see what happens in the next few days. One of my cables on the bay door broke today, I don"t know if I should try and find one or make one. I guess I should drive to Quartsite and test drive my new clutch, I havent had the nerve to test drive since installing it.I will check on the windows at Walts RV.
Will talk soon
Dave ( Dreamweaver )

[jjrbus]

 Thanks for telling us that, sometimes I think it is just me!! The only people who do not make mistakes are people who do not do anything and liars.

[John Z]

Great story, thanks for sharing it with us. As has already been said,,, there aint no one out here pointing fingers. We have all been in a similar situation. Sometimes all you can is smile, shake your head, and have a good little chuckle at yourself!

[Tin Lizzy]

I think today I will see if I can shave 1/2" off the back of headlight casing in hopes that it will clear the clutch.

[Dreamscape]

I cleaned our the area that holds the old OEM heater core and motors yesterday and today, along with lots of sprayed foam from a can. What a messy and time consuming job.

I noticed how the square headlights were installed on our 01 Eagle. Because I cut my gloved hand on their sharp jagged edges.

I hope yours looks better than mine, it looks like someone used a hammer and chisel to enlarge the opening. Something more to do to take up my time.

Happy Trails,

Paul

Dreamscape