Headlight assembly swap project

[myotis1134]

I screwed up guys. Back in the day, when headlights were still available at rockauto, I ordered a new driver side assembly but not a passenger side one. Now, I've got one clearish light and one yellowish one. Can't find a SHO headlight anywhere, can't find a sable headlight anywhere, and I'm fed up to the point where I'm about to do something very smart or very stupid.

I've decided to find a modern-ish headlight that is close enough in size and shape, and make it work. Ideally, it will be for a vehicle that's still new enough to have aftermarket versions, so we have some style options.

I'm currently browsing headlight shapes on amazon, and once I find a shape that looks right, I'll look for the dimensions. That's going to be the hard part. Mounting and wiring should not be difficult.

Now I have looked high and low, but have not come across a website which breaks down various headlight dimensions, so that will be the really hard part. If anyone is aware of such a site, please let me know.

My first candidate is the headlight which fits the 1999-2002 Chevy Silverado, 2000-2006 Chevrolet Tahoe, or 2000-2006 Chevrolet Suburban. The headlight is a two-piece affair, and the top part has the right shape. There are a few decent looking aftermarket variations, including LED. I have not looked hard enough to know if there are projector options.



I do not have the dimensions, but will start searching when I'm done here. If anyone has one of the vehicles in the ranges listed above, please be a pal and throw a tape measure on the upper piece. Just height and length will suffice. Also, if anyone has already seen a headlight on some random vehicle and thought it would look good on the SHO - please post it in the comments.

 

[Devin]

There is a thread somewhere here where someone swapped in headlights from an 04 Impala. I thought they looked good.

 

[Irish Pride]

It would be much easier to swap the header panel to a non SHO header panel and just use regular Taurus headlights. You can get regular Taurus headlights all day long on ebay and Amazon.

-Chad

 

[jrbarrie83]

Aren't the gen II SHO light assemblies identical to Sable assemblies, minus the light bar?

 

[Irish Pride]

Aren't the gen II SHO light assemblies identical to Sable assemblies, minus the light bar?

Yes, both are obsolete.

-Chad

 

[SHOrod]

Is the original lens too far gone to wetsand and clearcoat?

-Rod

 

[jrbarrie83]

Not sure the site is accurate, but they are showing available here:

https://www.buyautoparts.com/buynow/1995/mercury/sable/headlight_assembly/16-01084_an

Sorry - just realized this is drive side, and passenger side is showing out of stock. Maybe ebay? Search FB Marketplace for Sables being parted out?

 

[Irish Pride]

Not sure the site is accurate, but they are showing available here:

https://www.buyautoparts.com/buynow/1995/mercury/sable/headlight_assembly/16-01084_an

 

[myotis1134]

Is the original lens too far gone to wetsand and clearcoat?

-Rod

Already been done twice. I'd rather have clear lenses anyways.

 

[myotis1134]

I want a headlight that is brand spanking new, and something with clear lenses - not refractory ones. Also, I would like to find a headlight long enough to eliminate the fish bowl segment.

I have been watching a series on youtube which utilizes 3D scanners to reverse engineer car parts. This method may end up being the best way to address our headlight problem, but it's still going to be cheaper to find a semi-compatible existing part which requires some modification to the panel.

 

[Irish Pride]

I want a headlight that is brand spanking new, and something with clear lenses - not refractory ones. Also, I would like to find a headlight long enough to eliminate the fish bowl segment.

I have been watching a series on youtube which utilizes 3D scanners to reverse engineer car parts. This method may end up being the best way to address our headlight problem, but it's still going to be cheaper to find a semi-compatible existing part which requires some modification to the panel.

Factory 1995 Taurus SE headlights.

-Chad

 

[skyshadow07]

^ That's a 20 footer for sure

 

[myotis1134]

Found another candidate - Nissan Silvia S13. Don't have dimensions yet, but it looks similar and has aftermarket design options. The corner-marker/blinker piece is separate, and may be shaped differently. This car looks very similar to the gen 1-2 SHO at certain angles. Even the brake lights looks damn similar.

 

[myotis1134]

2001 Toyota Chaser. Actually found dimensions for these. About to pull the specs off the car and see how far off we are.

 

[skyshadow07]

That is very BMW-esc

 

[luigisho]

Adam did it but I think that was a custom hood or bodywork also to fill gaps. I don't see it with a quick search. I think Toolman had it for a little while

here it is

 

[FastCAD]

Factory 1995 Taurus SE headlights.

-Chad

View attachment 91212

Hello Chad; I found this post and remembered that you

Factory 1995 Taurus SE headlights.

-Chad

View attachment 91212

Hello Chad; I saw this post and remembered that you posted awhile back info on this build. I would like a link to that post. Is this pic your Gen 1 with '95 SE headlights? What is that bumper? All of the questions are because I have knocked out my right side headlight (driver error) and we all know that there is no replacements and there are not many options.
Your help would be appreciated.
Thanks,
Joe

 

[Irish Pride]

Hello Chad; I found this post and remembered that you

Hello Chad; I saw this post and remembered that you posted awhile back info on this build. I would like a link to that post. Is this pic your Gen 1 with '95 SE headlights? What is that bumper? All of the questions are because I have knocked out my right side headlight (driver error) and we all know that there is no replacements and there are not many options.
Your help would be appreciated.
Thanks,
Joe

That car is a Gen2 1992 with 95 SE clear headlights. It belongs to a friend of mine. What do you have, Gen1 or Gen2? I might know a guy that has new RH headlights ; )

-Chad

 

[FastCAD]

GEN 1
Thanks

 

[zak]

On the Gen I's about the only upgrade was to add the PIAA driving lights in place of the fogs. You could also get a relay harness to supply direct (higher) voltage from the alternator directly to the headlights to prevent overloading the switch in the steering coumn plus far less voltage drop. Can't recall if higher output bulbs were available. A Xenon, HID or similar conversion would not work with the way the reflector and lens are arranged, you would get hot spots and dark spots.