Over the summer months I noticed that both of the headlamps rubber gaskets that go between the headlamp bowl in the wing and the headlamp plastic shell assembly were splitting/bulged at several points around the headlight. I asked our dealer if the gaskets were available from Morgan, they are not, you have to purchase the complete headlight assembly at a cost over £500.00 to get a new gasket!. ( not funny !! ). Working on the assumption that Morgan buy in a lot of its parts in the UK, I decided to strip one headlamp assembly down and see what the gasket looked like. Sure enough the rubber gasket fitted on our Plus Six seems to be a generic part. It is available from
www.holden.co.uk part number 010.606
The rubber splits were found to be caused by the four self tapping screws that hold the plastic headlamp bucket to the wings headlamp bowl, these had been overtightened causing the rubber to split and bulge, in addition, the plastic bucket had distorted by the overtight self tapping screws increasing the problem. I managed to straighten out the plastic headlamp bucket by slowly easing it back with parallel pliers. The rubber gasket can be replaced without removing the headlamp or its bowl, simply slip the old one off and the new on around the headlamp and then the plastic bucket. I also slightly increased the size of the holes in the gaskets where the self tappers go through using a hole punch, this allowed some wriggle room to align the gasket on the wings headlamp bowl.
The following photo shows the new gaskets to be fitted, ( front and back views ) they are exactly the same as the originals.
![[Linked Image]](https://tm-img.com/images/2023/11/21/Headlamp-gaskets.jpeg)
The next photo shows the headlamp exposed with the new rubber gasket fitted. The plastic headlamp bucket is the two adjuster type with the LED headlamps locator rim also held by a single self tapper screw ( bottom right is the lug into which the self tapper screws ). The headlamp outer rim/bezel is located on the plastic bucket by two tabs at the top ( where the red rubber grease is on the photo ) and also a single self tapper screw that goes through the rim up into the lower plastic headlamp bucket. ( also lower right in photo )
![[Linked Image]](https://tm-img.com/images/2023/11/21/Headlamp-exposed.jpeg)
The rim/bezel itself is in my opinion low quality, although made of stainless steel, it is very very thin ( around 30 thou ) and distorts easily, it is also slightly too large, so when the lower bezel holding screw is tightened to the plastic bucket it has a tendancy to jump off the top securing tabs, even though there is an inner spacer on the inside of the rim where the self tapper goes through. In the end I increased the depth of the spacer to pull the tabs in the bezel into the securing tabs in the headlamp bucket. Lastly the bezels upper securing taps have been made by simply bending the inner rim with pliers, its a cheap and not very good solution. See next photo.
![[Linked Image]](https://tm-img.com/images/2023/11/21/Headlamp-Bezel.jpeg)
There is both a headlamp bucket and a chrome bezel/rim available on the Holden web site, listed as Headlamp backshell Assy number 010.496 and a Chrome Headlamp rim number 54520650/R These both look very similar if not the same as those fitted, I am not sure yet though if they are direct replacements and if the Chrome rim could be made to replace the fairly flimsy stainless rim used by Morgan in the PLus Six.
