Square Headlights for the GMC

 

One of the major items I wanted to accomplish was the installation of the "square" headlights. I had a really nice set of Bosch H4 lights from my old Astro (RIP) and I wanted a part of the van to live on in the GMC.

I loved seeing the square lights on the GMC, and it is one of those items that you will either love or hate. My preference is the "love".

I got my kit, and discovered that I needed headlight retainers and buckets. I bought the kit minus headlights, but I was not aware I was not getting the rest of the parts. I went back to the Junkyard and got headlight buckets from a Chevy S-10 Blazer. As long as they are GM buckets, and the proper style, they will be fine.

Step one is to remove the old tatterered bezels and the round lights. This can be accomplished with nothing more than a cordless screwdriver.

I removed the adjusters off the mounts and the headlight dropped right out.

The next step is to take a 3/16 bit and drill out all 8 of the rivits that hold in the adjusters. You will discard these.

After this, you will mount the new adjusting block temporarily. The large tan mount is positioned to the outside of the headlight area, with the taper facing down. You will see how easy it fits in there. Install 2 number 8 screws in the block from the back, using the same holes you just drilled the rivits out of.

The black block (smaller one) mounts to the top position, with the rounded side toward the headlight.

after they are mounted in position, take a 1/8 drill bit and drill carefully through the big hole. That is the adjuster hole, so be careful. on the tan block, it is located on the far left, the black block its right in the middle of the two smaller holes.

After the "pilot hole" is made, remove the blocks and enlarge the 4 holes to a 5/16" size. I made mine a hair larger to avoid interference from the adjusters.

With this step completed, you can clean up the hole a little and the reinstall the blocks. Tighten them all the way this time.

at this time, lets move on to the adjustment that will be required on the bucket itself. You will need to make a 1/8 hole in the bucket about 1/2 inch back from the place where the holdback spring would have gone. You can see it below. The spring will fit in this new hole.

Install the spring in the hole, and line up the bucket into the area, and install the 2 adjuster screws. Be careful, its easy to strip the head of the adjuster. They aren't the best quality.

By the way, I did paint the buckets...LOL...Once the buckets are in, simply install the light and the retainer ring.

This is what you should have...One round and one square...

Test the wiring as well at this point...

Yep, it works...Like Huey Lewis said...It's hip to be square! I did have a issue with the headlight plug. Mine are ancient so they will be replaced tomorrow.

Looking good...Do the same thing you just did for the other side, and the job will be done. I took mine across the street to the elementary school and used the wall to adjust the lights...

I painted the new bezels to match the coach, and am letting them dry. I may just replace the front turn lights with LED's too while I am at it.