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Old 02-24-2022, 11:23 AM   #1
Bradnerboy
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Question How would you fix this headlight gap?

As a 100% newbie, I'm working through a 1993 Club Car DS project. I've recently had the body painted and I've purchased new LED lights. The tail lights fit like a glove, but the headlights do not. The existing hole for the headlight is too big and even the shape of the headlight (or of the body) does not align nicely. Retrofitting the new light with the existing body isn't easily doable.

I'd appreciate some input on how best to deal with the sizing issue and the top gap.

I've never done bodywork (can barely spell Bondo and have never used it) and I'm not sure what the best approach is to mount the headlights. At first, I thought some JB Weld plastic bonder might work, and while it may work on the lower edge of the headlight, there's too much of a gap at the top.

Should I fill in the width gaps with some material that would give me a strong surface to screw into to mount the headlights?

And for the top gap, should I consider a heat gun on the plastic of the headlight to help mold it to the shape of the cart body?
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Old 02-24-2022, 01:34 PM   #2
crash12888
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Default Re: How would you fix this headlight gap?

Since the outer edge doesn't look that bad (pic 3) and inner edge is close to matching the body shape (pic 2) , I would start by making two pieces of 2" wide by 5 or 6" long flat metal (to go top to bottom)and bend it to fit inside your body contour.
Drill the matching holes in them for your light assembly and try to slowly tighten the fixture down to the body.
Use care when tightening so not to crack the light housing.
Since it fits best, might start with the outer flange first.
Not sure of the housing material but like you stated, you could also try a heat gun to help out.
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Old 02-24-2022, 04:05 PM   #3
KEGDS
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Default Re: How would you fix this headlight gap?

Did it have factory headlights? The kits for those are different. It looks like you have a kit to add to a body that didn't come with headlights initially. You may want to look at returning them and get a set for oem replacement.
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Old 02-24-2022, 09:37 PM   #4
Fairtax4me
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Default Re: How would you fix this headlight gap?

Get the factory style light kit.
I think they cost more, but they are the only lights that will fit the factory cut holes.
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Old 02-27-2022, 02:27 PM   #5
Bradnerboy
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Default Re: How would you fix this headlight gap?

Quote:
Originally Posted by crash12888 View Post
Since the outer edge doesn't look that bad (pic 3) and inner edge is close to matching the body shape (pic 2) , I would start by making two pieces of 2" wide by 5 or 6" long flat metal (to go top to bottom)and bend it to fit inside your body contour.
Drill the matching holes in them for your light assembly and try to slowly tighten the fixture down to the body.
Use care when tightening so not to crack the light housing.
Since it fits best, might start with the outer flange first.
Not sure of the housing material but like you stated, you could also try a heat gun to help out.
I'm going with this approach. Got some flat metal from Lowes and some JB Weld.

Thanks.
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Old 02-27-2022, 02:27 PM   #6
Bradnerboy
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Default Re: How would you fix this headlight gap?

Quote:
Originally Posted by Fairtax4me View Post
Get the factory style light kit.
I think they cost more, but they are the only lights that will fit the factory cut holes.
As far as I can tell, they don't have them in LED.
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Old 02-27-2022, 02:28 PM   #7
Bradnerboy
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Default Re: How would you fix this headlight gap?

Quote:
Originally Posted by KEGDS View Post
Did it have factory headlights? The kits for those are different. It looks like you have a kit to add to a body that didn't come with headlights initially. You may want to look at returning them and get a set for oem replacement.
Too late to return them.
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Old 02-28-2022, 06:36 PM   #8
Fairtax4me
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Default Re: How would you fix this headlight gap?

Rhox makes a set. Or you can use the plain factory style light but put an LED bulb in it.
https://www.revolutiongolfcars.com/p...club-car-ds-93
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Old 02-28-2022, 09:19 PM   #9
dundeebarnbuggy
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Default Re: How would you fix this headlight gap?

I have had conventional bulbs in my lights for 5 years now. I use them for at LEAST 15 minutes a day, sometimes for an hour or more, 365 days a year and still haven't burned out a bulb.
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