Headlight strip and rebuild of main harness.

Has had an issue with his headlights.  Things would go bad, we would replace something like a relay and it would all work again, then a week later, pops another relay.  Even was going through a fuse every now an again.  So we just decided to hell with it.   He was changing out the entire front harness, everything, headlight harness, both marker and turn signal harnesses, heater and A/C harness, rad fan harness, then taking both his motors out and tossed in a box.  We took the entire front end harness that was pulled from my 85GT and the headlight motors, relays, everything and transplanted it into his car.   It was a major job, but he did have 2 or 3 people helping over the course of the day, we have an exchange student from Bahrain (I think thats how its spelled)  He just happened to know how to work on cars.  Then Nigel was over for a bit today and helping point out what was going on.

OK first pic, hood is off, and they are trying to get the damn headlight relay that seems to be melted fused together to separate.

OK drivers headlight is off, finally. Passenger headlight is next.

Now I was so busy with my car I was not able to take any pics of the middle of the job.  Suffice it to say, he had to remove both turn signals, both marker lights, unhook the horn wiring and relays, unhook the wiring to the heater motor, wiring to the A/C system, wiring to the brake warning switch, wiring to the windshield wiper motor, radiator fan, and we unhooked everything slowly fed it through the main front compartment.   Instillation was the reverse of it, its a long time consuming job.   But it sure went a hole lot faster than sitting there with a multi meter shaking wires trying to find a half broken wire or wire that is shorting to ground inside a loom.  We had to remove the upper A/C condenser bolts which are rubber grommets with threads.  They spun and would not remove I went for the air cutter, Rashed out student, grabbed a small pry bar and went "Pop, Pop" and both the stubborn bolts popped out. 

   Thats Rashed, looking over it and thinking, that was kind fun.  He was the only guy not complaining about the heat. 

Tim double checking the bolts for the headlight brackets. Granted the way his hand is on the nose, kinda looks like he is whispering to the car, asking if it is happy to have working eyes now.

Whoo Hoo they work.

Anyone know how to put this stuff back on.  We actually thought about black tape, but it wouldn't stick.  I told Tim we could (and this does work)  Drill a few small holes in the plastic then use mechanics wire like needle and thread to stitch around the joints to make it stay in place.

They Even Go Down now on there own.