It can be assumed that B/L engineers had made the headlights retractable for looks, streamlining and protection, but had overlooked a small detail and failed to provide headlight protection in the retracted position.

So I designed a protective plate that would accomplish this, adding to the function and safety of the car.  The simplicity of the design makes it very easy to apply this added protection, as drilling, cutting or any modification of the body work is not required.  The parts needed for the modification are as follows:

1.  (2) protective plates as per Figure 1. ( click here for large diagram)
2.  (4) angle brackets as per Figure 2. (click here for large diagram)
3.  (10) 1/4 inch hex head bolts and nuts.
4.  (20) 1/4 inch flat washers


Step 1 - Protective Plates Fabrication

The protective plate can be fabricated from either aluminum plate, sheet metal, or (my preference) corrugated plastic sheeting (the kind used in 'house for sale' signs).  In any case you want it to be rigid and lightweight.  Cut the shape and hole locations as per Figure 1. Remember you'll need two.  Then, to give it that factory-made appearance, paint them black on both sides and let dry.


Step 2 - Angle Brackets Fabrication

Either make the brackets from scratch, or buy them ready-made from your local hardware store.  These should be readily available. You'll need four.  Drill the mounting holes as per Figure 2. 


Step 3 - Installation

Mount the angle brackets to the two existing holes on the outside of the sub-frame.  See installation Figure 3 (click here for a large diagram). Place the front of the protective plate inside the bumper, on top of the bottom lip. Align the hole in the protective plate with the existing hole in the bumper
that was originally made for fog/driving lights attachment.

If fog/driving lights are an installed option on your TR, use the bolt that secures these lights.  If they are not an option, reach over the top of the protective plate and place a bolt and washer through the aligned holes threading on a nut and washer.  Reach over once again, and place two bolts and washers through the aligned holes of the angle brackets and protective plate, threading the nuts and washers on these as well.

One side's done; repeat for the other side.  Too easy. Now, stand back - or should I say squat back - and admire your handywork, knowing that your expensive lights are fully protected.

Louis Juhasz