Discovery - headlight conversion to 2003 on lights

This site contains affiliate links for which LandyZone may be compensated if you make a purchase.
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.
 

Attachments

  • P1050561.JPG
    P1050561.JPG
    459 KB · Views: 18,993
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 ;)
 

Attachments

  • nearside showing cuts 20mm from inner edge and level with btm plate.JPG
    nearside showing cuts 20mm from inner edge and level with btm plate.JPG
    134 KB · Views: 3,660
  • ns after front panel removal.JPG
    ns after front panel removal.JPG
    180.1 KB · Views: 3,840
  • os view showing cutout and inboard mounting.JPG
    os view showing cutout and inboard mounting.JPG
    142.4 KB · Views: 3,727
  • os view from underneath showing inboard mounting and cutout for lower headlight.JPG
    os view from underneath showing inboard mounting and cutout for lower headlight.JPG
    129.6 KB · Views: 4,746
  • os view from on top showng cutout near mounting point.JPG
    os view from on top showng cutout near mounting point.JPG
    104.2 KB · Views: 4,499
Last edited:
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
 
Back
Top