FIA (Le Mans) Headlights
I have recently converted my car to the FIA headlight setup. Because I autocross my car, the major benefit of this conversion for me was the substantial weight savings over the stock units. The complete setup uses the aluminum buckets and the plexiglass bubble covers to protect the bulbs. A normal purchase package will only include the buckets and covers, all lighting hardware must be supplied by you. For my setup, I used the original Corvette headlight cups and alignment screws, and screwed and nutted them directly to the aluminum bucket. This setup may not allow much adjustment of the light beam, as the flat surface of the bulb cup rests against the flat surface of the bucket. Another option, which is probably not very desirable to anyone, is to cut out the plate from the stock bucket which the alignment screws are mounted on, then drill holes through the plate and the bucket and screw and nut that. The drawback here, aside from cutting up the stock buckets, is that the bulb will sit forward from the bucket about an inch, which may look weird. The plexiglass covers generally come oversize and must be cut to fit properly. The mounting method is up to you, but one of the classic ways that race teams did it (which is the way I did it) is to use a hinge at the front of the cover, with screws drilled and carefully tapped into the plexiglass. The hinge is then held to the body using screws and nut, with holes drilled through the body work. The hinge allows the headlight bulb to be changed without completely removing the cover. The top side of the headlight must also be held secure so as to not flip open. I accomplished this (at the recommendation of Kevin Mackay, who restored the Rebel and Stars and Stripes cars) using a threaded insert which presses directly into a hole drilled in the fiberglass. Take a look at the pictures, and I will be happy to provide any other info.