Headlight Conduit Identification

A - 1928-early '29 headlamp conduit made from brass. These were used with all Ford "H" headlamps. I believe this is an original which was chrome plated during a "restoration" 40-50 years ago.

B & C - These are both 1929 headlamp conduits made of brass and nickel plated. These were used with 1929 type Twolite Headlamps. I suspect one of the two was Ford's design and the other an alternate design from an outside supplier. If there were usage dates specified by Ford for either or both is unknown at this time.

D - The common rustless steel headlamp conduit used throughout 1930-31 on passenger cars and Deluxe commercial models.

E - 1930-31 rustless steel horn conduit. All horn conduits followed this pattern but were mad of nickel plated brass in 1928-29.

F - 1930-31 non-metallic conduit (composite image). These were used on standard "A" and "AA" commercial models which had black enameled headlamp cases. These were designed for use with the new 1930 style commercial bodies which were introduced in late June 1930. They MAY not have appeared in production until August 1930.

RANDOM FINDINGS:
- The extended length of the headlamp conduits varied all years. I have a fairly large sampling and all types ranged from 7" to a little over 8". The majority fall between 7-1/4" and 7-3/4" long. As an example of variation, I have a pair of each of the '29 type conduits shown which came on a single vehicle in each case. The length from one side to the other differed by approximately 1/2". The longer of the two has just over two additional spiral wraps

- I don't have a suitable sampling of horn conduits to provide a range on the lengths.

- The outside diameter measures .485"-.490" on the 1928 type headlamp conduits and all horn conduits. The larger Twolite headlamp conduits average .545".

- Of approximately 20 samples of the "rustless steel" conduits, all are magnetic stainless except for one lamp conduit and one horn conduit which are non-magnetic.

- It's important to note that the telltale sign of original conduits the shape of the end bushings on each type. I've never seen any replacements or reproductions that match up although I believe A&L makes the latest type good enough to fool the casual observer.

Finally, the photo below shows a few NOS non-metallic headlamp conduits. Note the difference in the design of the bushing at the headlamp end. I suspect these were made in the mid-late 1930's as service replacements. The few used originals I've seen as well as archive photos that show the conduits all show the design above.

 NOS headlamp conduits for Standard commercial models

 Source:   http://www.abarnyard.com/workshop/conduits.htm

Model A Ford Headlight Conversion to Halogen Headlights

Several years ago, I purchased at a local automotive swap meet / flea market, a pair of vintage 1928-31 Model A Ford headlights.  Back in 1928, headlights used low light intensity incandescent light bulbs.  This was fine for the day when vehicles didn’t travel very fast or were not in great numbers on our highways.  Now it is best to be seen when you are driving not only at night time but during the day.  So for safety sake, I would suggest using modern light bulbs in your custom car or hot rod.  Headlights now offer improved lighting distances for night driving, and great visibility for being seen on the highway when driving in the day time.  One of my main objectives in the build of my 1929 Model A Ford roadster is to use as many of the modern day safety features in the hot rod as possible.

Stock 1929 Ford Model A Headlight Reflectors

As with most things when building a custom car or hot rod, you can buy whatever your heart desires as long as you have the funds.  Another one of my goals in the hot rod is to complete the build as cheaply as possible.  Now with that said, there is the time element.  Whenever you forego the option of buying something and decide to fabricate it yourself, the time to finish the hot rod increases.  For me, it is the challenge to create, fabricate, and develop as much as I possibly can.  This is what will make my 1929 Ford hot rod roadster very unique from all of the others.  Now let’s get to the actual headlight conversion

Over the last number of years, I have bought and sold many cars, either in a complete form or parted them to pay for the 1929 Ford hot rod project.  One of these cars was a 1991 Ford Mustang.  I sold many parts from this car, kept several, including the headlights with the intention of converting the old Model A Ford headlights to halogen lighting.  These sat around in the shop for a couple of years before I actually got around to this.  Now that I am very close to having the 1929 Ford hot rod on the road, headlights are important.

The first step in my conversion process was to cut out the section that was used to contain and hold the halogen light bulbs.  I used air cut off saw for this.  Of course the friction from the cut off wheel created a bit of heat in the plastic head lamp housing resulting in the plastic to melt around the cut.  This was not a problem for me, as I was intending to mount this roughed out bulb socket from the head lamp into my metal lathe and round it up.  I suppose you could use the drill press and a two inch hole saw for this provided you had a safe way to hold the head lamp housing securely while drilling.

With the socket removed and turned round on the lathe, place the socket on the Model A Ford head light reflector.  Using a pencil trace the socket outline.  The Model A Ford headlight reflectors that came with my vintage headlight, were not in great shape.  These were perfect for my experiment.  One reflector was all dented and the other had no silver on it.  This conversion will be the proto type for a much better set of reflectors later on.

Before I could enlarge the hole in the Model A Ford reflectors, the original headlight sockets needed to be removed.  Using a pair of pliers, the sockets twisted off without any problems.  The die grinder fitted with a variety to burrs. The socket hole was enlarged to the required diameter.  To finish this step off, a larger grinding wheel in the die grinder was used to perfect the shape and diameter.  I did notice that one of the Model A Ford reflectors had very brittle metal causing larger pieces to be torn away rather that ground away.  This was a bit hair raising.  The other reflector was easy to enlarge and did not have the same problem.  I’m not sure why this happened as both reflectors were made of brass?

The modified 1991 Ford Mustang headlight sockets were then attached to the Model A Ford reflectors using only two #6 by 32, half inches screws.

In order for the halogen light bulbs to fit inside the vintage Ford headlights, the back side of the halogen bulb needed to be trimmed.  The rear plastic portion of the bulb shielding the electrical terminal /plug needed to be trimmed even with the electrical terminals on the bulb.  This is also necessary to allow soldering of wires to the terminals.  With the terminals exposed, they now needed to be bent back 90 degrees.  The original wiring plugs for the halogen light bulb was 16 awg, so I soldered new 16 awg wires to the halogen light bulb terminals.  The wires are about 12 inches long.  A plug will be made later on to attach the headlights to the hot rod.

Five minute epoxy was use to seal the terminals and the newly soldered wire connections on the bulb.

As an in term measure, I decided to paint the Model A Ford reflectors with a high heat silver paint that had decent reflective properties.   These newly modified reflectors using halogen bulb will do till I replace the reflectors later on.  As luck would have it, I found in the workshop two identical stainless steel mixing bowls that would make perfect reflectors in the Model A Ford headlights.  As a future post, I will have a video, showing the entire process of making new headlight reflectors using parts from an old Ford Explorer and the stainless steel mixing bowls.  Both of these conversions will only cost me my time and no out of pocket expense.  I do intend to sell the first set I converted in the next while.  These would be perfect for a daily driver or rat rod.

Source: http://1929fordhotrod.com/johnsblog/2011/11/23/192831-model-ford-halogen-headlight-conversion/