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Assembly
Headlight mechanism I started working on cleaning up the headlight mechanism. When I took it apart it was completely frozen and the gear box on the motor felt like it was stripped. Here I found the problem; the headlight shafts were siezed in their bearings. These flange mounted bearings cost about $5 to replace but I had another idea.
Turning new bushing It occured to me that these bearings were probably a little overkill for the low speed the headlights operate at. I also figured if I replaced them eventually they would sieze up again. I decided to push the bronze bushing out of it's carrier and replace it with a bushing turned from UHMW plastic. Now, the only reason I did this was because I happen to have a lathe and a ready supply of plastic. Otherwise I probably would have just replaced them.
Unfinished parts Here are the pieces of what will be the headlight assembly prior to finishing.
Finished pieces Here are the same pieces after sandblasting and powder coating. The new plastic bushings are also in place.
Headlight motor Headlight motor installed. This is the larger Fiat x/19 motor. With this motor the bracket with the up-down limit switches is no longer needed.
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