just having a spare 200TDi front panel and a couple of new style headlights (Disco or rangie?) I thought I would have a go at fitting said lights.
Now I know the headlight boxes leave a bit to be desired, but Ii think you can get the jist if you see the pics and read between the lines.....
I have tried to leave as much of the structure ~(that was remaining) left to increase its strength.
First thing was to cut the headlight box front panel out.
The cut line on the inboard side was 20mm from the inboard edge.
The cut line at the bottom was level with the top of the bottom locating panel (20mm up from bottom edge of headlight box). This is continued down the side until it reaches the outside flange.
The sidewall is cut along the front edge of the outside flange.
The top is cut as close as possible to the underside of the slam panel as possible. (this can be cleaned up later.
After front panel removal
Offside showing cutout in slam panel for locating lug, cutout on lower lip for bottom headlight housing and the marking of the inboard headlight mount.
View from underneath of OS headlight showing inboard mount and headlight housing cutout.
View from on top of OS headlight showing cutout and headlight position.
to be continued