STAGE 78

 Return to the BUILD


“In this issue, you will assemble the parts of the right headlight and install it on your K.I.T.T. scale model.”

The assembly steps here will be identical to those in the previous stage, just using the right headlight.

Contents


Parts

Materials: The Right Headlight Bracket is metal and the other parts are plastic.

Magazine

  • The Series – Knight & Knerd (Part 2)
  • Build Your KI.T.T. – Step by Step

Build


Right Headlight

NOTE: I have slight changed the order of these assembly steps from the printed instructions.

Step 1

Press the Right Headlight Lens into the front of the Right Headlight Housing, orienting the ‘HALOGEN’ marking on it as shown:

Step 2

Retrieve your Body assembly from the previous stage and set it upside down on a soft surface. Locate the LED on the longer wires of the Headlight LEDs cable and press it into the matching hole on the back of the Right Headlight Housing.

Once this LED is installed, route the wiring around the back of the Headlight, as shown:

Step 3

Fit this Right Headlight Housing assembly into the Right Headlight Base, as shown:

Secure the Housing into the Base with two (2) OP screws, one on each side as shown:

Step 4

Fit the Right Headlight Bracket into the Right Headlight Base, orienting it as shown:

Secure this Bracket to the Base with two (2) TM screws – one on each side.

IMPORTANT: The tighter these screws are, the harder it will be for the Headlights to raise and lower. Ideally, these should only be tightened enough to hold the part in place and still allow it to freely pivot around these screws.

Make sure the Headlight LEDs wiring is routed above this BracketThis also is your friendly reminder to try using 3-in-One Oil on all screws going into metal:

Step 5

Fit this Headlight assembly to the right front corner of the Motor Bay Frame as shown, and then secure it into place with two (2) AM screws.

Make sure the Headlight LEDs wiring does not become trapped underneath the Bracket as you secure it in place:

Step 6

Center the Headlight LEDs wiring of this Headlight in the matching channel of the Motor Bay Frame, then secure the Cable Clamp over the wiring with two (2) LM screws.

At no time should any of these steps trap, pinch, or otherwise hinder the movement of the Headlight LEDs cable. In order for our Headlights to properly raise and lower, there needs to be some slack in these wires:

Step 7

Gently turn your Body assembly back upright and check for the proper movement of this Headlight.

As on the left side in the previous stage, these Headlights should naturally close (lower) on their own by the force of gravity alone. They may not close completely and that is OK – we will help them with the addition of springs in a later stage:

And again, we should also be able to easily open (raise) this Headlight assembly with a very light upward pressure. If you find either of these actions to be too firm or stiff, go back to Step 4 and try adjusting the TM screws:

Here, we have both Headlights installed and closing as expected:

Thoughts


I honestly remember when pop-up headlights were one of the coolest features when it came to cars of the 80s. Today, it is extremely rare to see them. When the next stages arrive, we will install the opening/closing motor and mechanism before testing their proper operation!

Next Up


 Stage 79 – Headlight Drive Rod/Rod End/Locks, Gear, Spring Levers, Springs

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