CARELLO SIDE MARKER LIGHT RESTORATION
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The Carello amber colored side marker lights are one of the most sought-after parts for 1969 Berlinas, GTV's and Spiders. I restored mine using Aftermarket Reproductions' replacement lenses. The restoration is very straight-forward and involves some welding, gluing and the use of a lathe. The first step in the restoration process is the removal of the stainless trim ring from the reflector, which is done by turning the assembly on a lathe. The assembly is held in the chuck by the plastic lens. Make sure the chuck is tightened firmly, but not so tight that it breaks the lens. Faint cracking sounds may be heard as the chuck is tightened, which are simply the lens undergoing stress. If the assembly no longer has a lens, put a large bolt through the bulb socket and use the bolt to hold the assembly in the chuck. I suggest cutting off the old lens and using the latter method. This method will reduce the chances of the chuck scratching the stainless trim ring. Use a bolt the same diameter as the inside diameter of the bulb socket. Place a large diameter washer and some padding to protect the stainless trim ring on the lens side. Place a washer on the bulb socket and slip the bolt through that washer, the bulb socket, and the large diameter washer. Lastly, put two nuts on the end and tighten. Make sure the two nuts are not over tightened because they could crush or distort the bulb socket. Only remove the portion of the trim ring that wraps around the back of the reflector. When removing the rolled-over portion of the trim ring, cut down flush with back of the reflector. In the photographs above, the assembly on the left has had the rolled-over lip of the trim ring cut off. Carefully separate the stainless trim ring from the reflector and the lens, or lens remains. Sand the freshly-cut edge of the trim ring to remove sharp edges. Discard the white, soft, plastic gasket or seal located between the lens and the reflector. The second step is the restoration of the reflector. If the studs are broken or badly damaged and in need of replacement, drill out the heads to remove them. The picture above shows the original studs on the left, the replaced studs on the right and a 25 X 4mm fine thread machine screw in the foreground. Spray the reflector surface with any highly reflective silver or chrome paint, and allow to dry overnight. The third step is to prepare the replacement lenses so that they will fit flush on the reflector. The base of the lens has a flared lip on it. File a small notch in this lip to fit the head of each stud. Make sure to center the lens on the reflector. Assemble everything to make sure it fits together well before applying glue. The fourth step is the application of adhesives and the fitment of all the pieces. Apply a small bead of GE Clear Silicone II Glue and Seal on the inside of the flared lip to act as a seal against the reflector. This seal is the new gasket. Next, apply a small bead of J-B Weld to the outside edge of the flared lip which will hold the stainless trim ring. Be sure not to apply too much J-B Weld. Place the lens on the reflector and a put a small bead of J-B Weld along the outside of the lower edge of the flared lip. This will glue the lens to the stainless trim ring. Now, slip on the stainless trim ring. Next, place the entire assembly into something similar to the clamp shown in the picture. I used a 1 1/2" 12-pointed socket. Place something soft between the stainless trim ring and the socket to protect it. Place this assembly in a clamp and tighten firmly enough to press the stainless trim ring to the lens, and the lens to the reflector. Next, put a bead of J-B Weld on the back of the reflector and up to the stainless trim ring as shown below. Following the directions on the J-B Weld package, allow it to dry overnight. Any slopped J-B Weld can be carefully removed with the aid of a razor blade. Be careful not to scratch the stainless trim ring. After mounting the "new" side marker light to the car, smear some grease on the threads of the studs and slip a short piece of aquarium tubing over each stud. This procedure should keep out moisture and dirt. The handmade replacement lenses are available in amber or red and will not fade. The lenses are available for $15.00 each from: Aftermarket Reproductions My special thanks go to the late Gary Valant who gave me the help and guidance I needed to complete this project. |
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