Extra Tail Light Modification
One of the things I noticed with my Pulsar was the lack of a light bulb in top section of the taillights. Upon pulling the assembly apart, I found that there was indeed room for another bulb, both with space on the plastic bulb assembly and in the lens assembly.
So, the first thing to do was to decide what kind of lamp I wanted in the space. I thought about just a brake light and also just a tail light, but the thing that turned me off these two was the fact that just a single pole bulb used for either stop or tail lamps would be far to bright (i.e. Looking like the brakes are applied all time), and considering I wanted to keep it simple, I didn’t like the idea of wiring in some kind of resistor. I decided to fit a double pole light socket so that the extra light was the same brightness as the others when just the tail lights were on, and also when the brakes are applied.
The first thing you need to do is find a suitable light socket to fit in the small space in the top part of the plastic tail light assembly. I tried a few different places, like auto electricians, and Repco, but found that the only ones they had were far too large for the space. You could also try a trailer shop where they sell tail lights as they use a very similar light socket. I was lucky enough to find the whole assembly at a wrecker for $5 cold hard cash!
The $5 tail light blub assembly!
If you have purchased the entire assembly, use a small drill bit (or large if you like!) to drill around the double pole socket (identified by the extra green wire leading to it). This will enable you to get a hacksaw in there and cut it out properly. You could also use a jigsaw here if you are lucky enough to have one.
Drilling out the light socket (and no, this isn’t the double pole one!)
Once you have removed the socket, use a hacksaw to cut down the side, around the bottom, and up the other side, then stick a flat screwdriver in the cut and twist to remove outer casing.
Removing outer casing from socket
Ok, so now you have your socket ready to be installed into your existing assembly. Use a pencil to put a mark on the rear of the assembly as shown in the picture. If you can, find a drill bit the same size as the new bulb holder, and drill a hole where you have marked. If you can’t find a drill bit big enough, like me, use the biggest one you can find and then make the hole bigger by melting it with a soldering iron. As the soldering iron will melt the plastic quickly, make sure you check for size with the socket. Once around about the same size, use a rounded file to smooth out the hole.
Mark
a hole for the socket
Use a file or Stanley knife to cut two little groves for the wires to fit through from underneath, and also make some groves in the walls leading to the other wires so the new wires have somewhere to sit neatly.
Grooves
Wire in the negative wire to any of existing black ground wires. And wire in the green wires to the two wires running to the double pole socket at the bottom (You may have try it in the car to make sure you have the two wires around the right way). Push socket into hole and wedge negative wire down the side.
Wiring
Neatly route all the wires alongside the others, push wires into grooves and silicon over the top to keep wires in place. Also, place a bead of silicon around the rear of the new socket. (Be careful not to stop the spring and contact pad from moving up and down)
Neat
Wires
Place assembly back in taillight and test. Sit back and admire your handy work knowing that you will be the envy of all your friends!
The
Finished Product
Questions? Comments? Death Threats? Contact: leigh.watt@alcoa.com.au
