Headlight Adjusters - gear teeth

[Spandrel]

I'm getting ready to machine a few of these so that I can finally put my headlights back together. I'm going to add a set screw and some loctite in there to keep the damn things from falling off - stupid press fit splines are a stupid idea in a vibratory environment.

I can machine these pretty easily *without* the gear teeth. Does anyone know what they are there for? It looks like the teeth are exposed at some point in the housing... perhaps there's a BMW specific tool to mesh with and turn the adjusters? (although I would think it would be easier to just turn the hex head on the back...)

[cartoonz]

the teeth are to mesh with a screwdriver to rotate the adjuster from a 90 degree angle.

I'd look into making a complete adjuster, not just the wheels - if you want to be really popular

[TxGR8White]

Phillips head screwdriver "catches" each of the teeth, making them turn in or out.
The adjuster wheels that were once offered by BMW had a setscrew in the hexagonal part.

[Spandrel]

the teeth are to mesh with a screwdriver to rotate the adjuster from a 90 degree angle.

I'd look into making a complete adjuster, not just the wheels - if you want to be really popular

What is the point of adjusting from a 90 degree angle? (in other words - I can make the things much faster and cheaper without the teeth, but if there's a compelling reason, I can try to add them)

I'm looking into turning a couple of sets of the bases as well... I think if I were doing a full kit, I'd want to change around how they work.

Phillips head screwdriver "catches" each of the teeth, making them turn in or out.
The adjuster wheels that were once offered by BMW had a setscrew in the hexagonal part.

Thanks - didn't know about the set screw. It's the easiest short term fix, that I could think of, without re-designing the whole system.

[TxGR8White]

What is the point of adjusting from a 90 degree angle? (in other words - I can make the things much faster and cheaper without the teeth, but if there's a compelling reason, I can try to add them)...

Because you cannot "easily" access those adjusters from the rear. The headlight bucket actually has a hole above where the "teeth" part of the wheel is located. Insert large Phillips screwdriver, and turn in the appropriate direction - simple.

[Spandrel]

Because you cannot "easily" access those adjusters from the rear. The headlight bucket actually has a hole above where the "teeth" part of the wheel is located. Insert large Phillips screwdriver, and turn in the appropriate direction - simple.

...so the teeth are only on the 'bottom' adjuster wheel? (working from a sample size of one here, so pardon the ignorance, please)

[Max Lumens]

LOL, great minds think alike. I have some at the machine shop now, making them out of 10mm SS hex stock. They'll eventually be part of a complete hardware replacement package, but also available separately.

[TxGR8White]

...so the teeth are only on the 'bottom' adjuster wheel? (working from a sample size of one here, so pardon the ignorance, please)

All adjuster wheels have the teeth...

[smc850ci]

I was able to drill and tap my existing ones and use an allen head set screw. No problems for 3 years so far.

[Spandrel]

All adjuster wheels have the teeth...

Got it. I'm going to look for an appropriate end mill for the CNC, and see if I can get the teeth cut as well.

Is there any interest from anyone else, if I get more made than I will use? (assuming they work)

I was able to drill and tap my existing ones and use an allen head set screw. No problems for 3 years so far.

Good to know it will work

[02540ico]

Got it. I'm going to look for an appropriate end mill for the CNC, and see if I can get the teeth cut as well.

Is there any interest from anyone else, if I get more made than I will use? (assuming they work)



Good to know it will work

Depending on price, yes. I have 1 that I could drill/tap, but the other is missing. I'd be interested in a pair for sure.

[hmfoster]

TXGR8white
Could you post a pix of where the adjustment hole is.
Thanks

[02540ico]

Any update on available adjusters??

[Spandrel]

Any update on available adjusters??

We've done a couple of test pieces in Delrin - I think we're ready to try aluminum and see how it works. I'll ping my guy and see if I can help him out this weekend.