So…
I have had issues with the headlight doors opening and closing since I got the car running a couple years ago. The doors would open, but slowly(&the passenger side even slower). They wouldn’t close at all, unless I did it manually. Well, I did search up some threads here on the forums about solutions to the problem(s). Having the actuators rebuilt, or buying rebuilt ones was out of the question(read:I’m cheap and $500 is a chunk of money for working actuators). I wasn’t interested in the electric conversion for the same reason. I did see that one of the Cougar supply houses sells seal kits to rebuild them, but they’re about a $100 to do both actuators…
Anyhow, I did find some information here about using Corvette seals and dust boots. So, I looked around and found a set of seals and dust boots(enough to do both sides) on ebay for $23 shipped. As some of you already know, it’s not a simple swap. The Corvette seals are quite a bit bigger in diameter, require some modification to the actuator. Below, are a few photos of the process. I probably have three and half to four hours into the whole deal.
Bottom line: Thanks everyone for the information here that has helped me get through some issues on my pile…
Here is the actuator after I removed the original(and destroyed) dust boot
This is the Corvette seal kit for C-3 models
I got a ballpark figure on how big I needed to open up the hole
I know… it looks like a total hack job. Not finished yet
After drilling all the holes, I used a small round file. It isn’t perfect, but the seal fit nicely
I apologize for not getting a photo after the dust boot was installed. I used a little bit of 3M weatherstrip glue to attach it to the actuator can