GTS covers - how to prepare them:
Above: how GTS cover is attached with tiny bolts (c). GTS cover is protected by scratches by a thick 3M film (b in blue color). Area above the 3M film (marked "a") is painted in matt black and creates an "eyelid".
Whenever working with the covers, tape up as much as possible on both sides. They scratch just by looking at them.
They are a little to tall to be able to fit into Fords tolarances for headlight. So I decided to cut the top off and glue on a 5.5mm polycarb sheet. It will need 4 stringers, each of them ~2 inches long and ~1/2 inch wide. They are easily made out out 5.5mm polycarb. Then heated up, and shaped by pressing them into their mounting area. This will not make them stick there. You would have to glue them on.
Apply gts cover on stock headlamps. Use black electrical tape to mark off where to cut on the outer vertical edge. Leave desired space (2-3mm). Cut with a dremel. Take your time, gts cover plastics boil early. Cut off the overhang on top of gts cover.
(alt 1 end)
Not really recommended. I tried using a clothing iron to decrease the high. In theory, the high would be reduced if when applying heat to upper section. Later on, during cooldown, just sitting on the shelf, it cracked because of too much internal forces. This was covered with a thick layer of Plastic Welder on the inside (not visible from outside).
2 years after end of production this crack has started to move upwards. There must still
be forces in the GTS cover.
(alt 2 end)
Mounting gts cover to lower bracket sheet:
From outer edge, between high and low beam bracket, should be 46mm.
Between outer side of mount bracket and cover should be 45 mm.
Front cover is able to withstand high winds according to OEM development standards, this equivalents to 85kg of pressure. I used 4 screws on top and 3 screws at the bottom. Stainless steel screws, 5mm in diameter.
Start making holes in the bottom of the gts cover. Make shure you don't hit the cover with the drill when the bit goes through - cover up with a cloth or something. Then mark and drill holes in bottom plate. Then make holes in botom plate of bracket. When you are 100% shure that front cover is finished, make holes on the top part.
Sideplates should not be glued in before the cover has all retaining bolts.
The following has been done to fix the crack in the black painted area:
Unless you look very hard, you cannot see the crack, nor the small area of uncovered front lens:
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