Talk Morgan Forums Morgan Sports Cars Morgan Three Wheeler & Super 3 Front headlight grubscrew

It's a setscrew having no head, typically with a screwdriver or hex slot turn it. Typical application would be to lock something to a shaft where the head cannot be proud of threaded hole.



In this thread the term is being used incorrectly to describe a socket button setscrew although I imagine most this side of the pond would understand what's being discussed.



Please don't ask what a flugel valve is though, or worse still a contra-rotating giggling pin

It's more confusing than a firkin of soup.

Hi Dan,

I started this thread to discuss , and get ideas , on how to remove the screw which helps retain the headlamps in position. In this photo you can see I have cleverly (!) rounded the hex drive in it such that I am casting about for ideas on how to get it out. Actually I had started to drill it out at this point but you get the idea.



Subequently I have drilled the old ruined screw out , and am in the process of retapping it one size bigger to take a screw with a head on it so if it seizes up again I can at least grab it with pliers etc.

Apologies - incorrectly assumed you were talking about rim screw

Nippy, I now see what you're talking about.

It looks like a poor design. Those headlights are used a LOT on street rods and hot rods over here and they never have s setscrew holding them in forward alignment.

But if you were going to have a setscrew, it would be better on the back side of the mount so it was not in direct path of crap from the road etc. I would also use anti-seize on the threads. I would take out the other side and to keep things in unison, drill out the other side headlight mount and over drill it as well.

Most setscrews are grade 8 in hardness and are very hard to drill out. You did great drilling out what you had.

I'm not sure, but you may be able to get by without the setscrew. If you used another serrated locking washer like the one you have on the wiring now, but adding it to the bottom of the top headlight bracket. This type of locking washers are very good in resisting rotation of the part being held in place. You just need another one or two up on top to lock everything into place. I would bet after that, you could not twist the tightened headlight with both hands. It may be good "enough".

Good luck and of course that was just a what if and my opinion. I have not true knowledge of how much vibration your headlights get out on the end of the mount like that.

Hi Dan,
I totally agree - those screws should have been on the back - if required at all as you say. Its done now so I will fit them anyway.
Again as you say I have overdrilled and finally ended up with M6 thread , M5 just didnt get enough depth with what was left - on both sides to keep them the same and fitted with copper grease.
While the headlight assemblies were apart I also smeared ACF50 grease everywhere to keep he rust at bay.
TO finish off I have also fitted headlights with built in DRL led sidelights as described on another thread , looks pretty cool and much brighter

PPS. A short length cut from the end of the right size Allen key inserted in the socket and given a good tap is probably the best answer and achievable if you do not have a drawer full of various punches to hand.

Thread Drift….Are the headlight buckets available from a Third Party in the USA?

Dan mentioned they are commonly used on hot rods, etc. I am looking for a replacement pair to have chromed.

They make things called "screw extractors" that you can drive into an Allen head and get it out. I had to resort to one to get a stripped one out of my Harley drain plug once (Rounded off by the previous owner)

http://www.sears.com/craftsman-5-pc-scre...mp;blockType=G5

Hi Kirk
I tried the smallest one out a set like this , it engaged quite well and I thought I have you now !

http://www.ebay.co.uk/itm/4-X-Speed-Out-Screw-Extractor-Drill-Bits-Guide-Broken-Damaged-Bolt-Remover-Set-/142130643712?hash=item2117a58300:g:LRYAAOSwZJBX~u-P

but it just chewed into the head even further. When that happened I decided to drill the whole screw out.
This worked for me , but I acknowledge I had some luck on my side as it could have easily gone very wrong.
That said I did it twice ?