I received an e-message from 1967beetle.com Reader and Author Joy Rabin, of California. She copied to me a message from Ryan Pettit of The Big Island in Hawaii. Ryan’s question—where to find some good front fender turn signal bulb holders for his 1967 Beetle.
From 1964 through 1967 the front fender turn signal housings are essentially identical—identical lens cover, identical lens, and almost identical bulb holder—EXCEPT that the bulb holder is fitted for 6 volt application 1964 through 1966 and for 12 volt in 1967. The bulb holder for 1967 has two terminals because the parking/running light has moved from the covered head light bucket to the turn signal. The bulb holder now had two electrical spades and the bulb had two filaments.
1968 through 1969 turn signal housings are, for all practical purposes, the same as for 1967 except that each chromed lens cover is cut-back on the sides to reveal the bulb’s light as a “side-marker”. To accommodate to this new lens cover, the lens is fabricated to fit the contour of the new lens cover.
It is my studied conclusion that the bulb holder reflectors for ’67 through ’69 are less robust than for previous years. This comes into play later in this exercise.
Ryan, Joy, and her husband Gary, and I looked around the Internet for replacement bulb holders for 1967 Beetles. I spent time speaking with the representatives of 3 major vendors. All agreed that no one today manufactures an identical replacement for the 1967 through 1969 bulb holder.
In fact, today’s replacements have only one electrical prong for the bulb holder’s single filament bulb (according to what I found). This thwarts the reasons for the twin filament which was new for 1967. And, it is just plain maddening to those of us who want our cars to be correct!
What can be done about this problem?
First, we can scour the VW salvage yards and swap meets for used German 12 volt bulb holders with good reflectors. This is an excellent option! We just need to ask the right questions before purchasing. In other words, is the bulb holder free of rust and is the reflector in good condition without peeling or corrosion of the reflective surface.
We can place wanted ads on venues such as thesamba.com. This often will turn up additional sources of used German parts.
There is another solution. I mentioned above that it appears to me that the 6 volt bulb holders had more robust reflectors. Ryan and I talked about this via telephone. We discussed ways of removing the good reflectors from 6 volt units and transferring them to 12 volt units.
I dug out a number of both 6 volt and 12 volt bulb holders and turned them this way and that, trying to remove the reflectors by a couple of methods. Nothing worked. I didn’t want to damage the fragile reflective coating.
I told Ryan that I would try a method which I had been considering. I chose an afternoon and assembled my tools for the purpose.
For my trial run, I selected a bulb holder which had no redeeming features—the reflective coating was long gone. The holder itself was in poor condition. Here goes!
My tools for this part of the job were my Dremel tool and accessories. Years ago, I acquired a flexible extension which allows me to lay the tool itself on the bench or hang it on something. This frees my hands and allows greater mobility. From the accessory box, I chose a cone-shaped small grinder and installed it into the Dremel.
Working carefully, I began grinding at the edges of the rivet securing the reflector to the housing bracket. I worked from the backside in order to avoid damaging the reflective coating. In about 5 minutes, I had ground away enough of the rivet to reveal the bracket
hole. I made a depression in the center of the rivet…just to have things more on my side.
I selected a nail set as my punch and, using my trusty ball-peen hammer, with a little effort I knocked the rivet free of the bracket. Laying the reflector face down on the padded workbench, I knocked the rivet the rest of the way through the reflector—working from the backside.
By comparing a number of bulb holders, I determined that there were two manufacturers: Hella and Hassia. The German bulb holders are clearly marked as to manufacturer. The two have some minor design differences and these differences define which reflector can be installed on which bulb holder bracket. The Hella reflector does not align with the Hassia mounting bracket and vice versa.
The next thing after matching a reflector to a bulb holder was to do a trial riveting job.
The Germans must have used a metric sized rivet originally. I had to drill the hole in the bracket slightly larger. I did the same to the reflector. Now, the head of the rivet would fit perfectly—just.
The riveting was a simple operation. Install the rivet from the reflective side of the reflector. Using a shorter shank rivet reduces the need for clamping more than once. No damage was incurred during the process, and the rivet held the reflector securely to the bracket.
Now, the biggie is, of course, to find either good 12 volt bulb holders with good reflectors or to find good 6 volt bulb holders with good reflectors which can be cannibalized for use on the 12 volt holders.