Am I doing something wrong? I seem to have far too much spacing. With the spacers in, I don't even have to notch the bucket, but the lights hit the bumper.

ran in to same problems as Madscience_7 did...dremeled that metal piece off...hella fucked up my front kit in the process... =(

http://i81.photobucket.com/albums/j2...K/IMAG0208.jpg

http://i81.photobucket.com/albums/j2...K/IMAG0209.jpg

http://i81.photobucket.com/albums/j2...K/IMAG0210.jpg

I thought this was gonna be plug n' play?...lol... now my headlights won't open all the way...i have to force it open, spent hours trying to figure things out, dremeling more in the process... then i just gave up... now my headlights are permanently up for the time being... 'til i figure something out.

Have you guys tried adjusting the inner headlight bucket screws? (Top and side going from the black inner bucket frame to the actual headlight housings assembly). You may have to adjust the spring some in that case, I don't know. The chassis that we set up the spacers for cleared the stock bumper. If everyone is having the same problem I can send out thinner spacers but for us everything fit.

I can visibly see they are sitting out too far... we used a 3/4 spacer, with a 1/8" nut... that = 7/8" which is the thickness of those large spacers. I think we adjusted those inner headlight bucket aiming screws first though which would bring the entire assembly IN
If you're on AIM shoot me a message -> sakebombgarag

... also your rear socket seems to be attached wrong and can bind at the back of the headlight bucket when the lights are raising up. It should be connected/rotated so that when engaged the wire points towards the fender.

https://www.rx7club.com/attachment.p...1&d=1302499173
https://www.rx7club.com/attachment.p...1&d=1302499173
https://www.rx7club.com/attachment.p...1&d=1302499173

http://www.youtube.com/watch?v=tpG5PlvWQTE

also try removing the nut and lock washer from behind the cylindrical spacers.... i swear 7/8" worked for us ...... it's a damn tight fit but there is still 1mm clearance (we did trim those rubber flaps a tiny bit). I think the aiming screws need to come in.....

UH OH!! I think I just realized the mistake. When we made the original spacer design we did it solely with the cylindrical spacers... it came out to 7/8" . I somehow missed the fact that the landing (on the black bucket) for those screws is actually indented, so when I ordered the side spacers I ordered 7/8" .

Can someone put a straight edge across the face of the bucket (and then put a ruler on the indented section of the bucket and tell me the difference?). I can special order/overnight some spacers to compensate for that discrepency quickly and send them out as soon as I get them. I'll need someone to measure that difference though. Sorry guys... I dropped the ball here pretty bad :( . I was in a rush to get them out and have an FC headlight bucket assembly here, but didn't get a chance to go back and re-test them on a car. We'll get it sorted, and quickly. Sorry again guys........ :(

-Heath

would it be possible to use a smaller spacer?

oohhh i see...and after all this time, i thought i was doing it wrong:scratch::lol: well i won't be able to touch my FC 'til this sunday...long work week starts tomorrow...this past weekend was the only weekend for me this month to actually put in work in the FC...so let me get this straight...once you get the right measurements, you'll get new spacers made and send them to us correct?...man..just wished i caught this sooner...so i didn't have to hack up my front kit:sad::icon_no2: oh well i guess...it's all trial and error...just gotta move on and hopefully you get us the correct spacers.:icon_tup:

Yes and yes. I just need to get the difference measurement, and ill order up the new spacers. You should have called, emailed, PM, IM, pidgeon message me if you ran into issues. I left all our contact info at the bottom of the install guide :lol: . Again, sorry for this issue, I thought we were squared away but in the rush to get the spacer kit made I missed the indent on the original mounts :(

it's cool, not mad at you guys, i'm just mad about the fact why this installation process was taking so long lol...but things are clarified, hopefully you can get those needed measurements ASAP! i've been wanting to learn how to do small body work anyways..some bondo, a little sanding...spray can...my front kit will be fine :lol:

Just got your email Heath. Haha I was wondering why nothing seemed to be right this afternoon when I tried installing mine (unsuccessfully). I ended up ditching the spacers entirely and dremeled the crap out of the headlight bucket so it fit all the way in, only to realize the spacers were there to keep the back of the headlights from getting caught when moving up and down. My other problem is I cant get the painted cover off the top of the headlights. The screws are stripped. Any suggestions? Also, no worries Heath, we all make mistakes. As long as in the end everything works out as it should is what's important. :icon_tup:

Just got a chance to stop by Peter's place and measured up the difference. Looks like we actually need a 5/8" spacer instead, so I'll get those ordered tomorrow morning with new hardware. Again, sorry everyone for the hangup... if I had an FC at my disposal this whole process would have gone much smoother :(

If you guys want to do a temporary fix while waiting for the extruded aluminum spacers to show up, you can put a 5/8" anything in back of the lights on the sides so you can at least use them for now. Hopefully we'll be able to get this stuff shipped out late this week/early next.

Stripped screws... PB blaster and let them soak for a day... if that doesnt cut it... you'll need to get a screw remover tool. It's possible to do it without removing the cover, just not easy.

I got mine to work, goes up and down no problem. Did a rough trim on my shrouds, they fit as well, albeit a little roomier to compensate for the increased travel arc.

I will try the smaller spacer when you guys send it, will come back with results!

After aiming them, the lights are out of this world.

I had a serious problem with those screws too. I stripped 5 of the 8 out with the Phillips, even using a nice bit in my 1/4" ratchet. I slotted those 5 with the dremel to use a flat head screwdriver, but still ended up drilling out 2. New hex head screws from the hardware store were $.23 each. Damn metric fine thread.

I used a vise-grip carefully to remove mine, I didn't dare try with the screwdriver :(

My car was painted by the previous owner. And they painted on the screws.... So there is a strong bond. Im gonna use PB blaster and then replace with hex head screws for sure.

ETA on the new hardware?

Preliminary results:

http://i55.photobucket.com/albums/g1...4-12205205.jpg

I had these installed before finding out the spacers were too large, so I ended up doing a number on my shrouds :(

WOW!!! There's a noticeable difference. :icon_tup:

Early this next week (hoping monday). The replacement spacers are ordered and on the way to us, and I'll get them in the mail the day they get here.
-Heath

Any updates on the spacers?

yes, the spacers came in today.... they are packed and I'm making labels for them now. They should be in the mail (USPS) tomorrow morning.

damn only if i had 759 for headlights. but i need to fix my motor. : (

you guys should have your "real" spacers shortly ;)

Thanks man!