LANDROVER DISCOVERY LIGHT CONVERSION

PAGE..1...2...3...4...5...6...7...8...9...10...11...12

GUIDE TO LOCATION OF SPOT WELDS

SPOT WELDS AT TRIPLE SEAM BELOW FRONT WING

SPOT WELDS AT TRIPLE SEAM BELOW FRONT WING-SHOWING SEAMS FOLDED UPWARD - THIS SEAM MUST BE RE-WELDED OR SECURED

PANEL READY FOR REMOVAL - SEAMS DENOTED BY GREEN LINE REQUIRES TO BE RE-WELDED OR SECURED BY NUTS/BOLTS

PANEL BEING REMOVED - YOU MAY HAVE TO PRISE SEAM APART WITH HAMMER/CHISEL

MORE WELDS BEHIND PLASTIC DEFLECTOR - AT RED LINE.

NEXT PAGE

Once all the previous parts have been removed, its now time to start the not so nice part of the conversion as the metal panel that the old headlight was mounted on has to be removed. This is really the point of no return as once the panel is removed there is no going back.

There are different ways of approaching this, one being to fit a metal cutting disc to an angle grinder and just cut the panel out but this can leave a bit of a mess so I decided to remove the panel by drilling out all the spot welds.

You can use a special spot weld remover drill bit for this purpose but I did not have one to hand so just used an ordinary 7mm drill bit instead.

The following photos show the locations of the various spot welds to be removed, pay close attention to the folded seam under to top of the front wing, from the outside drill the visible spot welds out, then fold the outer metal lip upward, this gives access the the seam below and again the spot welds must be drilled to separate the remaining 2 panels.