I found a solution which allows me to mount 7″ headlights that are better suited for the period and styling of the car. The problem I was having is that most 7″ headlight housing are actually larger than 7″ in diameter due to the front side adjusting screws and retaining ring tabs, but the opening in the Lancia body is only about 7.25″—not enough room to mount standard 7″ headlight housings.

I initially used LED headlights that have a rear-mountable housing but they didn’t look right (bottom picture). Also, I seriously doubt their DOT rating because the beam pattern is more like a floodlight.

I ended up using headlight housings for 5.75″ bulbs and 3M 08609 urethane glass adhesive to bond 7″ E-code Hella reflectors into the adjustable housings (top picture). I used a structural epoxy adhesive to glue bolts into the mounting holes so the bolts won’t turn when I tighten the mounting nuts. The 3M glass adhesive has a 1200 psi tensile strength and if you’ve ever removed a windshield from a newer car you know how strong this stuff is. The adjuster screws are not accessible from the front, but the screws have a slot cut into the opposite end which is accessible from behind the headlight, under the tilt front.

Will the reflector housings fall out? Will the 3M adhesive cause the glass housing to heat unevenly and crack? Good questions, I guess I’ll find out.

I’m also looking for another front turn signal/combination light that looks better on the car.

New tires arrived and I received a brake master cylinder with a larger bore which should give me better brake feel. This week I’ll also work on hooking up the electric power steering pump to the quick ratio steering rack. I need to make a bracket to mount the pump and make the hydraulic lines, plus wiring.