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16 Sep 2012 22:36 #23553 by stroker
Replied by stroker on topic Installing headlight lenses
Gents- Reading the trouble Frank is having installing all the headlight goodies, especially the lenses, I'm wondering if I could take my whole headlight assembly out of the fender (marking the original position of the bucket in the fender first) and do the assembly on the bench so I can see what i'm doing, then reinstall the assembly in the fender. It scares the dickens out of me installing the nearly irreplaceable lenses using the Braille method!

Any comments most welcome!

Pete Rhoads
pete rhoads, restoring 810 phaeton 2241 H

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11 Sep 2012 15:50 #23472 by
Replied by on topic Headlight fun
Pete, the advice Josh gave to never take a part off that fits is sound!


The part with the most risk of breaking something is fitting of the lense to the surround(Better term?) and reflector.
I do this on the bench and then fit the assembly to the housing on the car.

There is no reason to be scared, just very carefull .

I rig a cable and winder so I can see what happens when I open and close the lid.This lets me see what goes wrong.
Have fun,
Frank

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08 Sep 2012 21:08 #23449 by stroker
Replied by stroker on topic Installing 810-812 headlight lenses
Gents and Frank- I'm really scared after reading the blog on Cord 810 headlight installation! Would a good way to do this assembly be to remove the pan/swing assembly of each headlight and put the whole assembly with the lens together on the bench, and then put the assembly(s) back into the fenders? We have the assembly fitted and they open without interference now (no reflectors or lenses), and as we remove the assembly we'd tape off reference points so we could replace the whole assembly back in so there's no interference.

The cost and rarity of my original lenses really motivates me to do this process CAREFULLY!

Pete Rhoads, somewhere under 2241H
pete rhoads, restoring 810 phaeton 2241 H

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31 Aug 2012 16:44 #23391 by 1748 S
Replied by 1748 S on topic Headlight fun
Hello Bill. I have a headlite cover thats for the early cars. If you can post a picutre of what you need maybe we can work out something. My cell number is 562 3187718.. My name is gary. Hope to help you out if possible.

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28 Aug 2012 20:15 #23388 by RandyEma
Replied by RandyEma on topic Headlight fun
Bill it is pot metal there are a number of ways to fix it epoxys or A.C.D. co 918-251-3161. Randy

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28 Aug 2012 18:48 #23387 by wcoye
Replied by wcoye on topic 810 Headlight Housing
Hi all,
I'm new to the forum but have been lurking in the shadows for years.

My Westchester sustained significant fender damage in transit. Although I think I'm well on my way to getting repairs made, I wondering if the the headlight housing is cast metal and if so, what metal.
The exterior cover of mine has a substantial Tee shape crack running from the screw above the lens to the center of piece. Is the piece damaged beyond repair or can this be welded successfully? I'm not too comfortable pumping epoxy into it.....unless that has proven sucessful for others.

Thanx in advance for your help.

Bill Coye
Cord 2240A
Bill Coye
Westchester 2240A
Brag line: Winner of the
2014 Hillsborough Concurs Strother MacMinn award

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04 Jul 2012 06:53 #23134 by
Replied by on topic Headlight fun
Josh, I found the article you did about headlights way back, should have read it before I started fiddeling with all the bits!

The glass is about 3/8 higher so that accounts for the rub.Will look into getting the correct ones.
I have no measurements for the height of the reflector, maybe someone can help there?
A friend in the US is checking out if the sockets fit.

Frank

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20 Jun 2012 23:09 #23076 by Josh Malks
Replied by Josh Malks on topic Headlight fun
I use replacement Cole-Hersee sockets, but I do not recall whether that is the number. It has the same three prongs that fit in the assymetrical hole circle in the Cord reflector. The same socket fits reflectors made for Chrysler products too, but is then upside down in the Cord. (Low beam points upward, etc.) Perhaps some other Forum viewer has the numbers.
Josh B. Malks
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20 Jun 2012 15:58 #23073 by
Replied by on topic Headlight fun
Josh, it's the best I can hope for at the moment.

Another small puzzle are the lamp sockets.
The original ones are about shot.
I've found the 27018 at Cole Hersee. Do you know if it is any good?
I havn't found anyone in Europe that carries it, but who knows.

Thanks
Frank

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20 Jun 2012 15:43 #23072 by Josh Malks
Replied by Josh Malks on topic Headlight fun
Frank, your middle paragraph is a laudable and practical goal.
Josh B. Malks
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20 Jun 2012 15:36 #23071 by
Replied by on topic Headlight fun
Josh, I understand about NEVER removing it once it fits! <!-- s:lol: --><img src="{SMILIES_PATH}/icon_lol.gif" alt=":lol:" title="Laughing" /><!-- s:lol: -->

I'm not aiming for perfect on this go, but would like the lids to close (nearly)flush,
to open enough to light up the road, not to scrape paint off on every opening and closing
and to work every time the handles are cranked and the lights turned on.

I'll put up some pictures end of next week.
I'm taking a short break.

Frank

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20 Jun 2012 14:59 #23070 by Josh Malks
Replied by Josh Malks on topic Headlight fun
How about some photos, Frank.

The Cord headlight is a 3-dimensional puzzle. Getting it right is very difficult. Getting it near perfect is very, very difficult. Most important, once you are satisfied with it [u:1nq86oy0]never[/u:1nq86oy0] remove it again.
Josh B. Malks
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20 Jun 2012 14:53 #23069 by
Replied by on topic Headlight fun
And more fun!
The reflector hits the lid frame(getting this all on paper in english sometimes seems as
big a puzzle as the Cord is <!-- s:wink: --><img src="{SMILIES_PATH}/icon_wink.gif" alt=":wink:" title="Wink" /><!-- s:wink: --> )before closing completely.
I'm not yet ready to grind down the frame. Hopefully a good night's sleep will help.

The lower clip holding the reflector to the lampring
also hits something.

Frank

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20 Jun 2012 14:29 #23068 by Tom_Parkinson
Replied by Tom_Parkinson on topic Headlight fun
Hi,

Well, here's another Cordundrum that I have to look forward to! <!-- s:lol: --><img src="{SMILIES_PATH}/icon_lol.gif" alt=":lol:" title="Laughing" /><!-- s:lol: -->

--Tom
With brakes, two cylinders are better than one.

Editor-in-Chief Emeritus, The Hardtop News Magazine, the Journal of the Michiana Dunes Region, Lambda Car Club International

See pix of 1509A here: mbcurl.me/YCSE

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20 Jun 2012 11:21 #23063 by
Replied by on topic Headlight fun
The wings already have bulges from the gear segments hitting in the
(over)closed position.
Now to get it all to close with reflectors and lamp sockets fitted.
Well, just another (Cord)puzzle.

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20 Jun 2012 02:30 #23060 by Josh Malks
Replied by Josh Malks on topic Headlight fun
Indeed. Poor original design.
Josh B. Malks
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15 Jun 2012 08:54 #23051 by
Replied by on topic Headlight fun
Josh, thanks.
Both lids had the lips broken off, so I had to fabricate new ones.
Missed the stopscrews <!-- s:oops: --><img src="{SMILIES_PATH}/icon_redface.gif" alt=":oops:" title="Embarassed" /><!-- s:oops: -->

Now I get to take it all apart again.Great!

The stopscrew sets against the top of the wing I suppose?

Thanks
Frank

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14 Jun 2012 15:13 #23047 by Josh Malks
Replied by Josh Malks on topic Headlight fun
See 810 Service Bulletin #21. It's stop screw #5.
Josh B. Malks
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14 Jun 2012 15:04 #23046 by
Headlight fun was created by
I'm putting the headlights back in the Cord, getting the lids to close
near to flush without scraping off the paint was a lot of fun!
I think I've got most of the other problems sorted.

The one thing I have not found was a way to set the closed
position of the lids.
Can anyone point me in the right direction?
Thanks
Frank

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