Jaguar XJ6 - 7-Inch Euro Headlight Conversion - As Jag Intended!!

Today we get to share an upgrade for your US Spec Jaguar XJ6 - upgrading the outer headlamps to the correct the look of your Jag by installing parts for a 7" headlamp conversion.
The issue is that US Spec Jags, due to DOT regulations requiring anything with quad headlamps use only 5.25" bulbs at the time, used a blanking plate bezel that doesn't look quite right.
This does require sourcing a 7" spec bezel, and replacing the underlying bucket and associated hardware. But, it's not that hard, and it's well worth it!
Steps should be very similar on S1 and S2 cars as well, but this is shown on a 1983 Series 3.
This video took a long time to make because we ran into issues during the job - but hopefully that helps you understand what is needed. Our issues were silly - me saving the wrong bezels from a Euro spec car 25 years ago, and having to source new ones, and then me not realizing one of the bulbs was built crooked. So I did my best to edit around these, and give as much good info as possible. Hope you enjoy!
Special thanks to Duncan's post on the Backglass.org that has great info and pics on doing the conversion. I ended up using similar clips: www.backglass.o...
PARTS and TOOL LINKS:
Jaguar Specialties Headlight Conversion Kits:
This is where to go to source new metal reproductions like we used:
www.jaguarspeci...
I used their bezels - since I had other parts from other cars, I called them up and ordered only the bezels. Very happy with their quality and fitment.
SNG Barrett carries plastic reproductions - I've not used these, but they may be an option you wish to try:
www.sngbarratt...
Conversion Parts (Except for the outer bezels):
Here's a list of individual parts if you wish to source bits and peices:
Note that links will point to parts fitting other cars - but these should be the right parts. The reason is that in the US, any headlamp parts for XJ6 S3 are 5.25" not 7".
Headlamp Bucket (2 reqd) - These have adjsuters as well:
mossmotors.com...
Headlamp Bulb Retainer (2 reqd)
mossmotors.com...
Adjuster Set (shouldn't be required if you are buying the buckets that come with adjsuters. But if not, you'll need 2 sets of these.)
mossmotors.com...
Rubber Headlamp Gasket (2 reqd)
mossmotors.com...
Inner Rim (2 reqd)
mossmotors.com...
Plug kit with grommet - this appears to be the same part number on several cars from the era. This MAY be a direct fit but may need extension of the wires. A great option if you wish to replace the wiring. (2 reqd if so)
mossmotors.com...
Amazon Parts:
Note that any links to Amazon will be through their affiliate program, as a result Vortex Garage may get a small commission. Note that we will only post items we have personally bought, or would buy as an alternative to something else discontinued.
SYLVANIA H6024 SilverStar High Performance Halogen Sealed Beam Headlight (7" Round) (2 reqd)
amzn.to/38GoGLb
(Due to other reviews noting crooked bulbs, you may prefer to buy this in town to ensure both are correct, or check when they arrive and get a replacement if needed.)
Headlight wiring connector:
KASLIGHT Ceramic H4 Sockets H4 9003 HB2 Wiring Harness H4
amzn.to/3DWWLlI
Self Tapping Screws Assortment Fasteners Set, 650pcs 304 Stainless Steel
amzn.to/3Krhz72
Grommet Kit - my Swordfish kit I used doesn't seem available anymore. there is a larger kit I'll link to, but also one alternative that may have the right grommets.
Alternative (cheaper kit) -
InstallGear 180pc Rubber Grommet Kit
amzn.to/3NWUsU7
Larger kit (more expensive but good to have in the shop) -
Swordfish 20040 - Master Black Rubber Grommet Assortment, [29 Sizes], Package of 189 Pieces
amzn.to/3KpOB7M

[@VortexGarage]

Chapters and Links in Video: Start/Intro - Why US has smaller lights: kzbin.info/www/bejne/kKfTgZlqdpmYodU Finding I had the saved the wrong bezels and sharing where to source 7" bezels:" kzbin.info/www/bejne/kKfTgZlqdpmYodU61 Other Parts Needed: kzbin.info/www/bejne/kKfTgZlqdpmYodU A few notes on headlight wiring: kzbin.info/www/bejne/kKfTgZlqdpmYodU Starting disassembly: kzbin.info/www/bejne/kKfTgZlqdpmYodU Building the 7" bucket assemblies: kzbin.info/www/bejne/kKfTgZlqdpmYodU053 Installing the buckets: kzbin.info/www/bejne/kKfTgZlqdpmYodU279 Dealing with crooked headlight bulb: kzbin.info/www/bejne/kKfTgZlqdpmYodU462 Resuming assembly: kzbin.info/www/bejne/kKfTgZlqdpmYodU583 Exploring options for bezel lower retention clips: kzbin.info/www/bejne/kKfTgZlqdpmYodU645 Making and using wire based retention clips: kzbin.info/www/bejne/kKfTgZlqdpmYodU785 Final Assembly and Testing: kzbin.info/www/bejne/kKfTgZlqdpmYodU853 Conclusion: kzbin.info/www/bejne/kKfTgZlqdpmYodU969

[@nathanbrown6091]

I have a 1976 jag xj6 and I think I have the euro ones. I’m doing a v8 swap with a fuel cell in the trunk. I’m very excited to see this old jag run and be reliable!

[@brianpeterson8253]

Two thoughts1) you are very talented and make great videos 2) it is issues like this that make me want nothing to do with old cars, especially jaguars

[@donporter8432]

What a huge amount of time you saved me! Thanks a million!

[@VortexGarage]

Glad it helped!

[@crs290]

Never assume that the NHTSA always knows what it's doing.

[@mescko]

Do they ever?

[@pakmak7241]

What are the inner headlights for, and how to Operate them (which button) ;)?

[@donporter8432]

They operate as high beams I think. Anybody confirm? Thanks

[@omgitsBenjamin]

Your front orange side-marker didn't illuminate with the headlamps!? One of many small items to fix I'm sure 😅 I have a 1986 and I thoroughly enjoy it.

[@VortexGarage]

Yeah I fought with that and got them working and now they're out again 😂. Need to remove them and really clean the socket contacts.

[@donporter8432]

Wow, what an ordeal! But perfect results. 👍