Headlight lens alignment...not light pattern.

[Trapdoor2]

Yes, I know this is a bit silly and I am really the opposite of OCD...but also a retired engineer/draftsman/CAD. I like symmetry, I notice crooked pictures on the wall.

While futzing around with the headlights, (installing "adjustable" LEDs from Snyder's) I noticed the headlight lens flutes/prisms are not straight (vertical), they're "sad". Left is (/), right is (\). It wouldn't be so bad but they're not symmetrical...it has one, somewhat lazy eye. The actual angle off plumb is probably just one or two degrees (no, I haven't measured it...but I did consider that).

I've been reading the service bulletins, various books and manuals. Searched the forum. Setting and adjusting the headlights is easy...but mine are maxed out inwards, no more tilt is available...and frankly, nobody seems to mention it (that I can find).

The headlight lens rings are located rotationally by the latch system on the bottom of the bucket and the lens is fixed rotationally by the notch and tab in the upper ring...I have fudged all the tolerances as much as they'll go towards straightening out the issue...still, the new child is a tad amblyopic.

Is there another way (besides the big spherical bolt, which is maxed out) to set the lenses rotationally? I have a couple of creative (hotrod) ways to get this done...but I'm looking for a more obvious, tried-and-true solution.

And...if there is none, I can easily leave it alone...at least until I get all the simple stuff done and need a silly afternoon project.

 

[nkaminar]

I was going to suggest the big spherical bolt but you said they are maxed out. I am surprised by that remark. I would have thought there would be more adjustment. Other than the big bolt you may try switching lenses right to left.

 

[rotorwrench]

The lenses are held into the rims with the springs that are shaped like little cow horns and they hold pretty tight. The lenses should be able to rotate either way in the rim but it may need one or more of the retainer springs removed in order to rotate them to align with the vertical center line of the bucket that is dictated by the upper rim retainer spring and the lower bucket latch.

I assume that these are original headlight assemblies but I use reproductions myself for my 1929 driver car. Either way, the rims should allow the lenses to be moved into alignment.

 

[Trapdoor2]

I was going to suggest the big spherical bolt but you said they are maxed out. I am surprised by that remark. I would have thought there would be more adjustment. Other than the big bolt you may try switching lenses right to left.

I did that (right to left)...in one of those "light bulb" moments. Made no difference at all. I may pull the spherical bolt out and see what's up in there. Could be rusty or be full of dead bugs...looks ok from the outside but it is certainly not using the entire sphere. I think the rectangular washer under the nut has a slotted hole that keeps it from using the entire spherical surface. Probably could use a good disassembly and cleaning.

The lenses are held into the rims with the springs that are shaped like little cow horns and they hold pretty tight. The lenses should be able to rotate either way in the rim but it may need one or more of the retainer springs removed in order to rotate them to align with the vertical center line of the bucket that is dictated by the upper rim retainer spring and the lower bucket latch.

I assume that these are original headlight assemblies but I use reproductions myself for my 1929 driver car. Either way, the rims should allow the lenses to be moved into alignment.

These are "Twolight", single-bulb assemblies, which I assume are original to the car (1931).

The lenses have a notch at the bottom which keys to the latch assembly. There's only about 1/16" of slop, which I've used to help...but it ain't enough. One of my "hotrod" ideas was to simply remove the tab, thus allowing the lens to be rotated to suit. Those springs are pretty tight (and a tad rusty), not sure if vibration would allow the lenses to dance around whilst driving if the tab was removed. I'd rather have them droopy than googly!

 

[nkaminar]

Try the large spherical bolts.

 

[Jim/GA]

I noticed the same slant in the lenses on my car the other day. It will bug me until I straighten them out. The big spherical bolt/nut should do it. We will see.

 

[rotorwrench]

I looked at my headlamps and the only conclusion I can come to it that Ford Made them that way. I like symmetry as much as any average person does but I don't sweat the little stuff like that. If I get stuck on perfection then I'd never get anything done.

The only other suggestion to tender would be to take a die grinder and a needle file to the latch keeper spring and make it fit the way you want it. Altering the glass lens could end up with a brokem lens. The light bar looks fine and there isn't much that can be done there. The dimples in the buckets are there to stay. Even if the mount bolt is bent a bit, it likely would lead to some other problem anyway.

The only way to really see a problem is to look straight at the headlamp unit from the front. Move a few degrees one way or the other and the problem goes away. Most folks don't look at them that close. I know I never noticed it before so I'm not going to worry about it now. When they designed those lenses, they were looking to direct the light beam in a specific manner. If it adversely affected the light beam, I figure they would have changed the design to correct it. In the modern era, we are now trying out different LED lights that would freak those original designers out if they knew. It was the quartz halogen before that but all these new type bulbs lead to problems directing and focusing the beam in the reflectors as was intended. The main thing is that you can see where you are going at night and you don't blind all the drivers heading toward you.

 

[Trapdoor2]

Yah, as soon as I get my seating sorted out and the distributor rebuilt, I'll pull one of the headlights apart and see what I can see on the spherical bolt. If it is an easy fix, I'll fix it...if not, I'll be happy with it as is. The latch keeper spring would need quite a bit of material removed, more than half its width. Grinding the notch in the glass to shift it would be easy. Miz Diane did the stained-glass hobby thing back in the 80s. Diamond files made for that work great. File it wider in one direction, epoxy a shim in the other side.

I'll check the spherical bolt first.

 

[katy]

I looked at my headlamps and the only conclusion I can come to it that Ford Made them that way

I suspect that's true. The highway safety regulations require the lights to not be horizontal and straight ahead, but actually slightly down and slightly to the right. I remember a spec of 1 degree, but I could be wrong.

 

[rotorwrench]

Just shedding more light on the subject:
The headlight beam alignment procedure in the Service Bulletins shows the set up that is based on the longitudinal fore and aft centerline of the car. The facing adjustment wall has that centerline in a vertical plane along with a 33-inch above floor lateral line and two 15-inch off main center line vertical markings for right and left beam center limits. With the beam at a focal distance of 25-feet, the elliptical beams should be centered overall with the center of each light beam 30-inches apart. The tops of the elliptical beams should be just at the 33-inches above the floor horizontal mark. This shows no indication of a rightward, (for left hand drivers), aim of the beams and was set up to keep the beams below the eye level of on coming traffic with car loading as a consideration. It was stated that it follows state laws of the time. Focus of the beam was to get the most distinct ellipse that was possible by the adjustment of the bulb high beam filament in the reflector. With the the high beam properly focused and aligned then the low beam would be in the proper position per the design of the lamp assembly.

Now this is an early SB so it was used during the period where the vertical fluted lenses were in use but they never updated it so that can be assumed that the procedure didn't change with the Two-Light lenses. The new lenses were designed to help get the best elliptical light beam shape at distance. With modern LEDs, focus of the beam is questionable due to the design of each different LED bulb. The quartz halogen set ups have their own reflector so focus should be adjustable in a similar fashion but I've never used those types so I don't know for sure. I don't know what the shape of the beam is on any of the modern bulb set ups. I still use the incandescent bulbs but even with those a person has to make choices. Originally the 21-21 CP bulbs were used. The 21-32 CP bulb came available but were not legal in all states. Eventually the 32-32 CP were a modern replacement and the 32-50 is the bulb that is likely still most used due to the obvious difference in brightness of the high beam from low beam. The internal placement of each filament was all that differentiated high from low beams in the 21-21 and the 32-32 candle power bulbs. I'm not sure if the LEDs just have less diodes for low beams or not but the have to have some change in brightness since most of the LEDs have no precise way to focus them in the reflector.

In the modern era, it seems that the government has sort of lost their focus on head lamp intensity. I'm older and perhaps more sensitive due to age but driving at night is fraught with every light intensity from dim to way too bright than it has ever been in our history, I try to minimize my exposure to night driving the older I get. Some of these modern headlight systems are doubtful in following any rules the government may have on the subject. Folks with super bright light systems might be able to see well but those opposite them on the roadway are blinded by their choices.

 

[BButturff]

My lenses are tipped (canted) like this too. I'm lucky that they both tip the same amount and in opposite directions. I would guess it's only about 6 degrees.

 

[David in San Antonio]

Many people cut back night driving as we mature (maturity is my doctor’s euphemism for getting older). I’ve definitely noticed greater sensitivity to oncoming headlights, or growing inability to recover sight after being dazzled. Trucks that have raised suspension make it worse. Some people have installed wide LED panels which disperse the extremely bright rays willy-nilly with no focusing lens at all.