Discovery - headlight conversion to 2003 on lights

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Just thought I would add to conversation. If I have done this correct there should be a pic of my old Disco which I converted to round lights as you will hopefully see.
 

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I've just carried out the facelift 2003 conversion this weekend to my TD5. I found that the two retaining push-in plastic nipples in the old indicators can be transfered onto the new lights providing the platic thread is cut off and replaced with a threaded section from a screw. Old screws are then removed from the new lights and the plastic nipples screwed in place allowing the new lights to plug into the wing.
 
I've just carried out the facelift 2003 conversion this weekend to my TD5. I found that the two retaining push-in plastic nipples in the old indicators can be transfered onto the new lights providing the platic thread is cut off and replaced with a threaded section from a screw. Old screws are then removed from the new lights and the plastic nipples screwed in place allowing the new lights to plug into the wing.

:nopics:
 
is there any reason that this conversion could not be done on a 200tdi
considering you could upgrade a 200 to a 300 type ..
 
An addendum....

just having a spare 200TDi front panel and a couple of new style headlights (Disco or rangie?) I thought I would have a go at fitting said lights.
Now I know the headlight boxes leave a bit to be desired, but Ii think you can get the jist if you see the pics and read between the lines.....

I have tried to leave as much of the structure ~(that was remaining) left to increase its strength.

First thing was to cut the headlight box front panel out.
45987d1369671598-discovery-headlight-conversion-2003-lights-nearside-showing-cuts-20mm-inner-edge-level-btm-plate.jpg

The cut line on the inboard side was 20mm from the inboard edge.
The cut line at the bottom was level with the top of the bottom locating panel (20mm up from bottom edge of headlight box). This is continued down the side until it reaches the outside flange.
The sidewall is cut along the front edge of the outside flange.
The top is cut as close as possible to the underside of the slam panel as possible. (this can be cleaned up later.


After front panel removal
45988d1369671598-discovery-headlight-conversion-2003-lights-ns-after-front-panel-removal.jpg


Offside showing cutout in slam panel for locating lug, cutout on lower lip for bottom headlight housing and the marking of the inboard headlight mount.
45989d1369671598-discovery-headlight-conversion-2003-lights-os-view-showing-cutout-inboard-mounting.jpg


View from underneath of OS headlight showing inboard mount and headlight housing cutout.
45990d1369671598-discovery-headlight-conversion-2003-lights-os-view-underneath-showing-inboard-mounting-cutout-lower-headlight.jpg


View from on top of OS headlight showing cutout and headlight position.
45991d1369671598-discovery-headlight-conversion-2003-lights-os-view-top-showng-cutout-near-mounting-point.jpg


to be continued ;)
 

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  • os view showing cutout and inboard mounting.JPG
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Hi Guys, i am looking to buy the connectors for this conversion, anyone know where i can get them from? Ebay has new ones at £25 plus P&P but was looking for cheaper ones
 
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