Round Headlight YJ - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > General Jeep Discussions > Builders Corner

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 03-13-2009, 12:48 PM   #1
Really?

WF Lifetime Member
 
ccain's Avatar
 
Join Date: Feb 2007
Location: SoCal
Posts: 6,453
Images: 9
Round Headlight YJ

OK, so I was cleaning out my pictures folders this morning and found these. I thought it would be fun to do a write up on the Round Eye YJ Conversion. So here ya go.

Bear in mind that if you try this, I or the WF bear NO responsibility for any problems you may encounter or the total destruction of your Grille!

OK, now that we've said that...

First, you need to plan your build and gather the parts. You'll need two 12x24 sheets of steel (Lowes), a box of 1/8 x 1/4 pop rivets, a rivet gun, a set of "Empi Bug Eye's" headlight buckets (eBay or any air cooled VW website), longer headlight adjusting screws (NAPA), Two 7" sealed beam headlights, the round turn signals of your choice (you can get really nice CJ turn signals from most high end off-road stores), the paint of your choice and poster board.

I took a bunch of measurements and cut out my template from the poster board. You only need to make one template as you can reverse one of the blanks when you cut it to make the other side.

Your template should look like this:



You can see here that I pre-measured all my rivet holes and used a small diameter hole punch to make them. This made it easier to pre-drill the filler panel once it was cut.

Next I measured to find out where to place the lights. Now, I can't remember the exact measurements but if you split up your template like this then find the centers you'll be just fine. Just eyeball it but leave yourself enough room for the tops of the headlight rings to clear the hood when closed.



Now that we have the main template cut we can place the headlight opening. Here's where it gets a little tricky. The opening isn't round like you'd think. and you'll need to cut 2 templates in order to line things up. Make your template from the mounting area on the back of the headlight buckets. Again, Make 2 templates... One that is solid with a center line and one that is cut out and fits the light buckets with reference point to line up the top of the bucket on the blank. They should look like this:

Template 1


Template 2


Using the solid template, line the intersection of the centerlines with the headlight center you marked on your big template. Draw the diameter of the headlight bucket. Now use the template you cut for the opening and place it in the circle you just drew on the template and mark your opening. This "opening" is what you need to cut out of the blank when you put it on the Jeep.
Measure twice, cut once!

Now, cut out your blanks. Make sure you have a nice clean work area with a flat surface. Use a Sharpie and mark around your template and transfer that shape to the sheet metal don't forget to mark the rivet holes (i spaced mine every 2"). Using an air nibbler or Jigsaw with a metal blade or (like me) extreme heady duty metal sheers and cut out the shape. I found it was easier to cut out the headlight openings after I attached the blanks onto the Jeep. Pre-drill your rivet holes.

Reference the body line under the headlight onto your freshly cut blank with a ruler. Now find yourself a nice sharp edge (the edge of your workbench or a 2x4 or anything you can use) and bend in the body line. It's not that sharp of a bend and you can eyeball that as well. Once everything is riveted down you'll be surprised at how nice it lines up.

Apply the blank to the Jeep and start drilling rivet holes into the grille. Start at the corners and work in (that way you don't need 6 hands). Here's what everything should look like at this stage:



When you cut out the openings, just know that the opening for the 7" headlights is a little larger than for the square lights. You will cut into the grille metal when cutting these out. I drilled 3/8" holes where the headlight openings are and cut the contour with my jigsaw.

After that it's down to the actual install and wiring. I had a blast doing this mod. At first, I was apprehensive because I was afraid of what the "purist" would say. After I did the mod, I found that even the purists were saying it was cool.

NOTE: You could also cut out the old metal face to the grille and weld these panels in if you so choose. I just haven't replaced my welder since the move out here. And besides, the rivets add a nice "Military" feel to the grille!

Hope this helps! Be sure to post or PM if you have any questions!!

ccain is offline   Quote Quick Reply
Old 03-13-2009, 03:08 PM   #2
Pushy, Loudmouthed, and Ballsy
 
Dare2BSquare's Avatar
 
Join Date: Jul 2006
Location: Driving Around Arkansas In My Black XJ
Posts: 6,177
You think I could do this on my XJ???

That would be REALLY different. A XJ with round headlights.

__________________
99 XJ Sport
4.0l
AW4
NP231
d30/C8.25
3" Skyjacker lift
31 x 10.50 General Grabbers


http://i66.photobucket.com/albums/h2...are/TMLogo.gif Are all fishermen liars, or do only liars fish?
Dare2BSquare is offline   Quote Quick Reply
Old 03-13-2009, 03:48 PM   #3
Really?

WF Lifetime Member
 
ccain's Avatar
 
Join Date: Feb 2007
Location: SoCal
Posts: 6,453
Images: 9
Quote:
Originally Posted by Dare2BSquare View Post
You think I could do this on my XJ???

That would be REALLY different. A XJ with round headlights.
I think round headlights look bitchin' on an XJ

XJ-8 Round Headlight Grille



ccain is offline   Quote Quick Reply
Old 03-13-2009, 04:29 PM   #4
Pushy, Loudmouthed, and Ballsy
 
Dare2BSquare's Avatar
 
Join Date: Jul 2006
Location: Driving Around Arkansas In My Black XJ
Posts: 6,177
I think I'll pass.

Guess I'm just too square.
__________________
99 XJ Sport
4.0l
AW4
NP231
d30/C8.25
3" Skyjacker lift
31 x 10.50 General Grabbers


http://i66.photobucket.com/albums/h2...are/TMLogo.gif Are all fishermen liars, or do only liars fish?
Dare2BSquare is offline   Quote Quick Reply
Old 03-13-2009, 05:08 PM   #5
Jeeper
 
cherokee980's Avatar
 
Join Date: Sep 2007
Location: Tomball Texas
Posts: 2,817
Quote:
Originally Posted by Dare2BSquare View Post
I think I'll pass.

Guess I'm just too square.
Amen brother!!!
__________________
my luck is so bad, It could be raining tits and I would get hit in the head with a dick!
cherokee980 is offline   Quote Quick Reply
Old 03-13-2009, 05:09 PM   #6
Wrecktrician
 
4point's Avatar
 
Join Date: Dec 2006
Location: Central Sierra
Posts: 7,351
It don't look so good on an XJ.
__________________
Just getting to work is an adventure.
4point is offline   Quote Quick Reply
Old 03-13-2009, 05:45 PM   #7
Jeeper
 
[TheYJGuy]'s Avatar
 
Join Date: Feb 2008
Location: Highland Lakes, NJ
Posts: 1,068
Send a message via AIM to [TheYJGuy]
Keep in mind that I'm too [square] as well for this, but I just have to say that I love your write ups Ccain. There's so much detail.
__________________
`
NJ Army National Guard
11Bravo
Ready for deployment.

So many mods planned for the upcoming YJ:
4.6ltr stroker
Dana44s
3.5" lift kit
33" General Grabbers
Massey Ferguason Grey body
Kubota Orange suspension components
lots more...

This is me on WF:
http://i221.photobucket.com/albums/d...ous/COMEDY.gif
[TheYJGuy] is offline   Quote Quick Reply
Old 03-23-2009, 07:41 AM   #8
Jeeper
 
scrambler1's Avatar
 
Join Date: Jan 2008
Location: vermont
Posts: 486
Are these templates printable to use? size wise? I am getting ready to paint my grill with durabak in the next couple of weeks. This would be great timing.
Any pics of the finished product?
__________________
94' wrangler 4 cyl. 5 speed D30/8.8 ARB
82' scrambler 350 TBI/700r4 D30/Currie 9"
07' JK sahara
Whats the deal with the facebook crap?? ->->->->
Grown men should NOT be on Facebook.
scrambler1 is offline   Quote Quick Reply
Old 03-23-2009, 05:46 PM   #9
Jeeper
 
jdhallissey's Avatar
 
Join Date: Aug 2008
Location: Gurnee,IL
Posts: 5,104
Send a message via AIM to jdhallissey
look up cain in the search bar he did this on his jeep well invented it. IT looks amazing-
jdhallissey is offline   Quote Quick Reply
Old 04-26-2009, 06:51 AM   #10
Newb
 
Jaik YJ's Avatar
 
Join Date: Apr 2009
Posts: 13
Are there any pics of this finished on the jeep?
On another forum there is a guy that swapped a TJ grill in. I think that is the route I will take when I flat fender my YJ I like the shape of the TJ grill better.
That being said those rivets would look killer on the front. I like the idea.
__________________
87 YJ 4.2L, 3 Tops, Full hard and soft doors and hard half doors, Nuttered, Weber 32/36, Flowmaster 40, 4inch RC, BrandonYJ 1inch Booms, 33x12.5 Baja Claws, Posi-loc, Round tail lights, 95 Mitsubishi Eclipse seats, Grant racing wheel, Homebrew front stinger, 4 fogs on bumper, 2 on windshield, Built on family rollcage, Xplod deck and 2 12's, 6x9's in homebrew soundbar.
Jaik YJ is offline   Quote Quick Reply
Old 04-26-2009, 08:04 AM   #11
Jeeper
 
buckshot500's Avatar
 
Join Date: Mar 2009
Location: Carolina
Posts: 798
This is a good idea, and the execution is well thought out. I'll even say it's much cooler than swapping in a CJ or TJ grille.

I just have to wonder how many CJ and TJ owners will use this method, to make their grills accept square headlights?
buckshot500 is offline   Quote Quick Reply
Old 04-26-2009, 08:24 AM   #12
that's what she said

WF Supporting Member
 
jgano23's Avatar
 
Join Date: Oct 2008
Location: \m/-_-\m/
Posts: 16,482
Send a message via AIM to jgano23 Send a message via Yahoo to jgano23
Quote:
Originally Posted by buckshot500 View Post
This is a good idea, and the execution is well thought out. I'll even say it's much cooler than swapping in a CJ or TJ grille.

I just have to wonder how many CJ and TJ owners will use this method, to make their grills accept square headlights?
0!!! just kidding. gotta keep that rivalry going .
jgano23 is offline   Quote Quick Reply
Old 05-07-2009, 10:48 PM   #13
Newb
 
Join Date: May 2008
Location: long island
Posts: 6
thats a prettty awesome build. but isnt half the fun of a yj the square lights? lol
oldskool2882 is offline   Quote Quick Reply
Old 05-25-2009, 07:32 PM   #14
Jeeper
 
BSahara1990's Avatar
 
Join Date: May 2009
Location: Norther California
Posts: 55
Images: 62
I just like the square because where i am at there is only like two other jeeps that have square. all others are round. so I'm sticking with my square but i have gave it thought to do a conversion like this but don't want to spend the time and money

BSahara1990 is offline   Quote Quick Reply
Reply

Tags
round headlight yj , yj headlight conversion

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
black headlight bezel robertv TJ General Discussion Forum 31 11-26-2010 05:38 PM
Headlight Conversion Kit-SQUARE TO ROUND Largemarge YJ General Discussion Forum 21 12-04-2007 03:13 PM
i need headlight adjusting bezels locked99 Classifieds Archive 2 08-23-2007 09:27 PM
Projector Headlight Man dohcv6 General Jeep Discussion 31 01-31-2007 10:27 AM
Headlight Wiring Help Needed for Newbie PaulW TJ Tech Forum 3 09-18-2005 09:59 AM



» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 10:55 PM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC