68 headlight cover size question

[Patrick N.]

Preparing my car for paint, I have discovered the headlight covers are two different sizes, (18.25" and 18.5" measured across the diagonal). I am sort of aware that 68 had 3 different size headlight covers that year. The metal bezels surrounding the headlights on my car are the same size, (part numbers are 3938115 and 3938116). The metal bezel for the right side is too large for the cover, cover measures 18.25 diagonal. The left side bezel is fine with the cover that measures 18.5" diagonal. I have some sort of obvious miss-match going on and would like to better understand what is typical and if I need to change cover size or bezel size or both?

Is it common or uncommon that a car would have two different size covers right and left in 68? BTW, The openings on the nose are also sized differently to accommodate the covers but the gaps fall within .01 and .014" which is the gap tolerances called out in the AIM.

Any insight is greatly appreciated.
Thanks,
Pat

[Rich G.]

Re: 68 headlight cover size question

I think there was a restorer article on this within the last couple of years or there was a thread on this board. I don't save the restorer so I can't look, but try a search here. What you remember is about the same as I do. I have a July built 68. If you want I can measure mine.

Rich

[Joe L.]

Re: 68 headlight cover size question

Preparing my car for paint, I have discovered the headlight covers are two different sizes, (18.25" and 18.5" measured across the diagonal). I am sort of aware that 68 had 3 different size headlight covers that year. The metal bezels surrounding the headlights on my car are the same size, (part numbers are 3938115 and 3938116). The metal bezel for the right side is too large for the cover, cover measures 18.25 diagonal. The left side bezel is fine with the cover that measures 18.5" diagonal. I have some sort of obvious miss-match going on and would like to better understand what is typical and if I need to change cover size or bezel size or both?

Is it common or uncommon that a car would have two different size covers right and left in 68? BTW, The openings on the nose are also sized differently to accommodate the covers but the gaps fall within .01 and .014" which is the gap tolerances called out in the AIM.

Any insight is greatly appreciated.
Thanks,
Pat

Pat------


I HIGHLY doubt that GM ever originally used a front surround panel with two different sized openings for the headlamp covers. Therefore, it's my expectation that the area of one of the openings has been "reworked" to accommodate the use of the larger headlamp door assembly. Most likely, this occurred as a result of collision repair at some point in the car's life. The "smaller door" 68 part is difficult to obtain so someone may have decided to use the later, much easier-to-obtain assembly and modify the opening to fit it.

[Patrick N.]

Re: 68 headlight cover size question

Thanks guys.
Rich, I will search some more and see what I can uncover. I'd be curious to see what your covers measure if its not a hassle for you?

Joe, I am under the same impression that my car had some rework rather than GM cutting different holes to accommodate sizes of covers -Wishful thinking that that was how it came. If GM used various sizes for the headlight covers during 68, did they also use various sizes for the cast metal headlight bezel surrounds to fit? My 3839116 bezel is larger than the 18.25 "smaller" door. Realizing I would like to correct the miss-match on my car, would it be OK for 68 to have the large 18.5" on both sides? That makes my life a little easier as I would need to purchase the second larger cover, but it does require me to cut the opening larger to fit the larger size cover.

Thanks again for the info guys!
Best
Pat

[Joe L.]

Re: 68 headlight cover size question

Thanks guys.
Rich, I will search some more and see what I can uncover. I'd be curious to see what your covers measure if its not a hassle for you?

Joe, I am under the same impression that my car had some rework rather than GM cutting different holes to accommodate sizes of covers -Wishful thinking that that was how it came. If GM used various sizes for the headlight covers during 68, did they also use various sizes for the cast metal headlight bezel surrounds to fit? My 3839116 bezel is larger than the 18.25 "smaller" door. Realizing I would like to correct the miss-match on my car, would it be OK for 68 to have the large 18.5" on both sides? That makes my life a little easier as I would need to purchase the second larger cover, but it does require me to cut the opening larger to fit the larger size cover.

Thanks again for the info guys!
Best
Pat

Pat------


First, GM did not cut the openings in the surround panel for the headlight doors. The panels were delivered to St. Louis with the openings already present. There were 2 different surrounds-----one with the "small" openings and a later one with the "large" openings.

Next, let's make sure we understand terms here. The BEZELS are the zinc diecast pieces which install from the front and surround each of the sealed beams. They are a finish trim item and have no real functionality. For all 1968's these were GM #3911143, left, and 3911144, right. It does not matter which door size the 68 is equipped with.

The HOUSINGS are the part to which the headlamps actually mount and the part which actually rotates on the bearings. The above-referenced bezels attach to it. The doors are part of the housings and are more-or-less permanently attached. The early "small door" 1968 HOUSINGS were GM #3932935, left, and 3932936, right. The later 1968 through 1982 "large door" HOUSINGS were GM #3938115, left, and 3938116, right.

[Patrick N.]

Re: 68 headlight cover size question

Sorry, die cast bezels 3911143 and 144 are the same size, those I have. The housings differ in size on my car. As you said earlier, it seems my car had one off the openings enlarged to accommodate the larger door for what ever reason. Based on your information, It now makes sense why things changed. If the bezels 3911143 and 144 were constant for 68, then early smaller housing do not fit. A gap would occur when those bezels were paired with the 3932935 and 3932936 housings and looks awful. I cannot claim to know what came on my car or why it was changed. That said, is a march car too early for the introduction of the later larger housings?
Thanks for the detailed info and setting me straight on this Joe.
much appreciated,
pat

[Rich G.]

Re: 68 headlight cover size question

Pat

I will measure mine tomorrow. The car is in my hangar. I think Joe has made it clear, but just for grins I'll do the measurement and post it tomorrow.

Rich

[Mark F.]

Re: 68 headlight cover size question

My August 6, 1968 built car has 18.5 doors (both sides) and the metal bezels are part numbers 3911143 left and 3911144 right. Happened to have them off the car at the moment. Back a few years ago I was communicating with another member named Terry. His email address was TFRINGO@AOL.com and he was doing a study on 1968 headlight doors. Not sure if he is still on the site. You may want to try and contact him as he went further than just the size of the door. He was also looking at the inside make up of the door, etc.

Mark

[Michael D.]

Re: 68 headlight cover size question

...I HIGHLY doubt that GM ever originally used a front surround panel with two different sized openings for the headlamp covers...

I agree.

[Michael M.]

Re: 68 headlight cover size question

My Nov/Dec, 67 built '68 has plastic (not metal) bezels which surround the headlights from the front. Would they have been replaced at some point in the car's life? I thought I read somewhere that there were both metal and plastic headlight surround bezels.

[Joe L.]

Re: 68 headlight cover size question

My Nov/Dec, 67 built '68 has plastic (not metal) bezels which surround the headlights from the front. Would they have been replaced at some point in the car's life? I thought I read somewhere that there were both metal and plastic headlight surround bezels.

Michael------

They're definitely replacements. The plastic bezels didn't even exist at the time the 1968 model was built. The plastic bezels were first used for the 1973 model year and became SERVICE for 1968-72 in March, 1973.

[Michael M.]

Re: 68 headlight cover size question

Oh gosh. I didn't know that. Are metal one's readily available?

[Joe L.]

Re: 68 headlight cover size question

Oh gosh. I didn't know that. Are metal one's readily available?

Michael-----


I would imagine that there are quite a few available in the used market but they are not reproduced. The only ones that will be correct for a 1968 are those originally residing on a 1968 or those from a 1972. The 69-71 have holes for the headlight washers.

[Michael M.]

Re: 68 headlight cover size question

Joe, thanks for the info. I checked ebay real quick and they are going for over $250 each! I think I'll be sticking with my plastic ones. Oh well, supply and demand, I guess.

[Joe L.]

Re: 68 headlight cover size question

Joe, thanks for the info. I checked ebay real quick and they are going for over $250 each! I think I'll be sticking with my plastic ones. Oh well, supply and demand, I guess.

Michael------



Here's what you need:

http://www.ebay.com/itm/1968-1972-Corvette-Aluminum-Headlight-Bezels-NO-Washer-Hole-/230842910938?hash=item35bf4f48da&item=230842910938&pt=Motors_Car_Truck_Parts_Accessories&vxp=mtr