Bosch Headlights, one with lens removed.
You can purchase a new reflector that is chrome plated with a halogen bulb base already attached. A kit includes 2 reflectors, 2 bulbs and 2 gaskets. The 6-volt kit #ELE207 is available from Restoration Supply Company in Reno, Nevada. It sells for $119.95 plus shipping.
The other option that I found is the one that I chose for this article. My local discount import parts man sold me Bosch Halogen headlight units without bulbs for $35 each. He also explained that this unit was being dismantled by some VW collectors to do essentially the same thing that I wanted to do.
The lens is glued in so the first thing is to remove the lens. Before starting the lens removal note that the lens is marked TOP. I took a black marking pen and made a mark on the reflector at this spot. This will help me place the new lens in its correct position when it gets glued in place. A very sharp knife will cut through the rubberized seal and enable you to remove the lens.
Clean up old adhesive. When all is ready apply new adhesive to the reflector flange. Noting the top of the lens and the top of the reflector put the two pieces together in proper position. For adhesive I used the 3M adhesive shown rght.
To make sure that the lens is completely centered on the reflector, slip the stainless headlight retainer over the light and clamp together while glue dries. I used a small bungee cord for a clamp.
Install new bulb in reflector and new unit in car. Make sure wiring connections are clean and charging system is working properly. Current draw will increase for the additional wattage in the new lights but the electrical system will handle it OK if everything is in good condition.
