986 Forum - The Community for Porsche Boxster & Cayman Owners - View Single Post - Driver's-side headlight tray -- I F'd up!

jluetjen · 11-01-2025, 04:35 PM

Note to self -- ALWAYS watch a YouTube video of a repair before starting.

I removed the old tray the hard-way -- be removing the HW with the tray from the car. It made sense since the new tray came with shiney new HW. I even got it out without cutting anything! But I digress...

Putting in the new tray -- the new HW just doesn't clamp on the sheet metal!

Looking at the other side, it's clear that the knurled adjuster clamps down on the sheet metal against the sleeved flat. What you can't see is the flange-nut under the adjuster that clamps against the inner sleeve.

But as you can see in the 1st picture, even with the flanged nut tight against the sleeve, the knurled piece isn't close enough the flat portion of the sleeve to clamp on the metal.

Am I missing something, or do I need to take out a grinding wheel to shorten the sleeve of the out-of-spec HW?

11-01-2025, 04:35 PM	#1
jluetjen Registered Member Join Date: Sep 2022 Location: Massachusetts Posts: 31	Driver's-side headlight tray -- I F'd up! Note to self -- *ALWAYS* watch a YouTube video of a repair before starting. I removed the old tray the hard-way -- be removing the HW with the tray from the car. It made sense since the new tray came with shiney new HW. I even got it out without cutting anything! But I digress... Putting in the new tray -- the new HW just doesn't clamp on the sheet metal! Looking at the other side, it's clear that the knurled adjuster clamps down on the sheet metal against the sleeved flat. What you can't see is the flange-nut under the adjuster that clamps against the inner sleeve. But as you can see in the 1st picture, even with the flanged nut tight against the sleeve, the knurled piece isn't close enough the flat portion of the sleeve to clamp on the metal. Am I missing something, or do I need to take out a grinding wheel to shorten the sleeve of the out-of-spec HW?