Automotive Archeology - S30 Headlight Bezel Variations

[Broman]

So during a trial refit of the panels of my May 71 240Z project I had an issue getting the lower lip of the LH headlight bezel ("sugar scoop") to lay flat against the upper lip of the lower corner valance.  While researching the issue, I quickly went a rabbit hole and discovered no less that FIVE variations of the S30 bezel, and the differences all seem to be related to the number and type of holes on the lower lip that overlays the top of the lower corner valance.

 

Here is the original fiberglass bucket, with two holes (#1 and #2) that align with the two cages nuts on the valance.  These holes are the same on all the variants.

 

But here is a bezel where an additional mystery hole (#3) shows up.  I have no idea what it is for, but it does have a matching hole in SOME 240Z valances.  (Other 240Z valances do not this this hole.)  This mystery hole seems to be continued on all further variants.

 

When they switched over to a metal bezel, they appeared to keep the same hole positions.

 

With the new 260Z bumpers that use a rubber filler between the bumper and the body, this filler has a metal tab that is screwed into yet another, albeit smaller, hole (#4) in the bezel.  And this hole has a factory-installed hex (not square) nut resistively welded to the back of the bezel to accept the screw holding the rubber filler.  BUT...when this nut showed up on the back of the bezel, a corresponding notch in the top of the corner valance was added so the the valance and bezel lips would still lie flat.  (This is what caused me a problem.  Some previous owner put a 260Z bezel on my car while keeping a 240Z valance and the nut gapped the panels...no bueno.)

 

When the 280Z grew a even larger bumper, this rubber filler strip was no longer used.  While I am just speculating, it appears that they did away with the hex-nut-welding step, but  left the #4 hole (no savings to delete it from the tooling).

 

This all is just one man's observations, and I welcome other findings y'all have made.

 

 

[zKars]

And here we are again with more evidence that there is something new to learn every single day. 

Thanks for the great detective work. 

[Broman]

On 3/5/2022 at 8:41 AM, zKars said:

And here we are again with more evidence that there is something new to learn every single day. 

Thanks for the great detective work. 

Well, allow me to ask my fellow 240Z owners to help with the detective work!

Here is my ask: If you have a 240Z with original METAL headlight bezels, please check them to see if you have this third mystery hole.  Even if your bumper is bolted on, I think there is enough gap between the bumper and the body to peek in and confirm/deny this hole's existence. And if you see it, is there a matching hole in the valence behind it.  I am trying to determine approx when this hole showed up.

[Parman]

I found another variation in the FRP fender extensions (sugar scoop), when trying the get my corner valance to line up.  After several tries, I finally realized the culprit was the sugar scoop itself.  My original one was cracked so bad, I sourced another one.  They are not the same.  The radius where the corner valance butts up behind is 1/10th of an inch thicker, making the length of that radius shorter.  My original 6/71 scoop is about .14" thick.  The other one is .24" thick.  In fact, the entire scoop may be thicker. One weighs in at 1 lb.  The other weighs about 2.3lbs.  Now to figure what date the thicker one came off of.  

[Yarb]

Great observation 

[Patcon]

Could you take a die grinder and thin the inside of the scoop to make the valance line up?

[Parman]

Thanks for getting me thinking about shaving off the inside, again.  That was my first thought, but my DA sander wouldn't reach the center area.  A die grinder would be hard to make it uniform with a small bit, however, I have a 7" flappy disc that would reach in there and get everything but a small corner.  That would make quick work of it, and be nice and uniform.  I could use the die grinder on that corner area followed by a file.  Thanks Patcon!

Richard 

[grannyknot]

Once the bumper is mounted it will be hardly be noticeable.

[Patcon]

A 2" rolok on a die grinder works like a small flap disc

[Parman]

7 hours ago, grannyknot said:

Once the bumper is mounted it will be hardly be noticeable.

Unfortunately,  I can't live with it the way it is.  It's noticeable on both ends of the corner valance.  I appreciate all the responses,  without this group, I would have never come this far.

[Parman]

Alright, I was totally wrong about these headlight scoops.  I thought since it was thicker,  it would be shorter on the inside curve.  When I measured it, it was exactly the same as my thinner bucket, so I didn't touch it.  Although they vary in thickness and weight, they fit pretty much the same.  Some kind of manufacturing genius.  Instead I focused on the center valance as my problem. And that is was.  The body work done on it had it curved in at the ends.  I got one from resurrected classics, and was so glad when I pulled it out of the box, that it was straight and my hunch was correct.   Had to modify the holes a bit on the ends but I'm very happy with it!