I decided with earlier darkness coming, it would be a good time to install that headlight relay kit, so I proceeded. Took the grill inserts out and went to remove the sealed beams to reach the plugs to disconnect them and I found that of the three screws holding the rings on each bucket, only two were doing any holding. The third or lowest screw on the lower portion was free turning on both. I found that nearly the lowest third of the bucket was badly rusted away, including that tab for that loose screw. Guess over the years since 1977 water getting in when driver in rain did it's deed. I can get it all back together tomorrow as the headlights were still held securely by the ring. I can even use a small wire or zip tie at that third screw hole for a little more support than was there.

No doubt though, the time is coming I'll need at least one more headlight bucket (I have one really nice OEM spare) but I'd take two. The mounts are fine (but I have one of them too) as they can get windage, but wind that dries water probably doesn't get between the sealed beam back glass and the bucket.

I recalled that I knew last replacement was some rust in the bucket, The rectangle bracket that the buckets sit in are the same right & left, but the buckets differ a little I see. I guess I should replace the springs while doing it, maybe adjustment screws too.

Driver side with a short lived visitor.

Pass side

 

Looks like dennis carpenter has new ones in stock, original tooling. Springs too.

 

DC https://www.dennis-carpenter.com/tru...W_-aOKa3KkgoFf

JBG has them. https://shop.broncograveyard.com/197...BoCoV4QAvD_BwE

LMC https://www.lmctruck.com/lighting/he...ArRLyjEZJBVyRl

 

Well, I got them secured, tied that third screw hole in the retainer ring with zip ties, not tight but just some snug. Everthing works, I'll order a couple ... and springs ... and get to it one day. In both, the other two screws are good.

Pass side.

Driver side


Actually, the big rusted away portion would allow drainage. I'll likely get them from DC, or I might just get one as I have a great, except for dust, like new extra passenger or "RH" side one. Not likely to were out another set huh?

 

 

Was my reaction too. Mounts behind them are fine.

 

x3 on that. I got a new one for my 74 passenger side which, shall we say, offered FULL drainage (Ie: completely rusted) but assuming they are secure, aligned and facing forward, job done I'd say

 

Well, I have a pair of great OEM buckets now, just need cleanup sanding and paint. Thinking about maybe drilling / punching a hole at lowest side to prevent water build up like obviously happened to my originals. I would do it up high enough to leave the seal beam supporting rim portion. I have a few punches or cutters that will work, they make nice holes too, thinking of a 1" hole?

 

Interesting you mention this as I had my new buckets out and thought much the same approach would be occurring for my install. I have a nice sheetmetal stepped drill bit which I plan on using. Knowing how drill bits can mangle sheet metal, I'd suggest drilling an 1/8" hole then step-drilling it out until it looks "right"

 

Oh yeah, I forgot ..... and I even have a couple new never used sharp. Good idea.

@mac.metalworks So ...... I cleaned them up, sanded where needed, used some graphite grey wheel paint on them, and cut those 1-1/4" OD drains with a step bit after a 1/8" pilot hole, after clamping each in turn face down on a work table top, clamp ran through hole. I first tried by hand holding to the table top, was doable ..... but the bit grabbed and suddenly it didn't seem to be so wise doing so by hand. I then smoothed the new drain edges and touched up with more spray. All the threads are good too.

 

Is there anywhere to purchase re-pops, the bracket that the bucket fastens to?

 

@77&79F250 .... aka: Rich.... listed three in his post #3 that I would think would be likely, if he himself doesn't have good ones.

• DC https://www.dennis-carpenter.com/tru...W_-aOKa3KkgoFf
• JBG has them. https://shop.broncograveyard.com/197...BoCoV4QAvD_BwE
• LMC https://www.lmctruck.com/lighting/he...ArRLyjEZJBVyRl

If not one of them, maybe Auto Krafters up there in Broadway, Virginia? I pretty sure I checked and DC had them.

• Auto Krafters Inc.

I recall them in the catalog. I noted that as bad as my buckets are, the mount that holds the bucket is really just some dusty / dirty.

 

Thank you, just bought a 79 and looking to convert it to 78 round like I did my current 78. I had bought the brackets and bucket from guy off fullsizebronco back 10 yrs ago or so. I can find buckets all day but not the bracket they bolt to it seems.

 

10-08-2025 .......... I knew that years ago I had bought a set of Unity 5" fog lights (bulbs are 4-1/2" OD PAR36, 5" is housing) off Ebay, then I put them up, and I guess I lost track of them. I recalled the purchase was from an estate sale, was thinking they had amber sealed beams. After we got home from town Wed. I got to digging, and then I found them, in the original box even .... still sealed inside a bigger tougher box. I thought they were used, but maybe not. They had been sent to me "priority plus" and the label was faded but with a magnifying glass, I could make out May 31, 2005. I opened them up, "FOG" molded in lenses in the glass, GE #4415 clear (not amber) bulbs, and everything about them is like NEW. I found the mounting parts inside too, wrapped in paper in the bigger box beside the Unity box.
I have set the box out, maybe tomorrow ....

Was glad to see them, been awhile. I've had ones exactly like them on a '69 Beetle, a '69 Dart Swinger 340, a '70 Chevy CST-10, a '73 Mustang, my '67 Chevelle had a set, and was a set on my '85 Gold Wing MC.

10-08-2025 ..........And Thursday (today), I decided since I want to make use of the Unity lights, was time to put them on. Wife was gone shopping with a friend. While I was at it, seemed like a good time to swap in those good headlight buckets too. I took the grilles out, was "getting into it". Once I removed the headlights, it was easy to grab the spring near the hook end with small vise grips and unhook them, then work the old rusty buckets out. One even partially collapsed as rust had weakened it, was worse than I thought. My "new to me" buckets slipped in easy on the adjusters, then I just grabbed the spring and hooked it. I did clean my bucket mounts and paint them. I was stumped then as both head light retainer rings had a tab come loose where they are electro welded at a factory. No way for me to fix that except replacement.
I got on the computer, found Dorman made a universal ring, pt # 42408 has 7 tabs, and it was said to fit, but calls locally pointed to "not in stock" .... but I found out was 3 at Advance Auto Parts up the road in Staunton, where my Wife just got back from shopping. Oh well, ain't but 40-45 miles round trip. Wife was already dressed, etc., so off we went, back to Staunton.

I wanted to compare the universal to my originals. I got there, looked them over, compared them, and 3 of the 7 tabs matched the 3 on the originals, AND the Dorman tabs were not welded on ... they were cut somehow with the whole ring before forming. I bought 2 and come home to install them, good fit, only cut one un-needed slotted piece off. I even used the longer screws. They are chromed steel, not a magnetic stainless steel.



I colored the 3 matching tabs red with a sharpie, & I just colored the 4 unused tabs with a black sharpie to hide them. The tabs are not just "attached", they are "one with the rings".



Put the grilles back in, they don't show unless you look for them.



I thought about cutting the excess tabs off, but decided not to. I'll put the fogs on tomorrow (Friday) then. The longer screws Dorman included are not #10-24 like OEM used, they are like a #10 sheet metal screw. I was gonna use the correct 10-24 ones, but a couple holes in my "new to me" buckets had stripped threads, but a squeeze with vise grips tightened the holes up and the Dorman sheet metal like screws were used.