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1994 Pontiac Firebird Formula Headlight, Power Window Motors & Interior Refurbish - Like New

We Go Resto On Our Project Lt1 Formula Before Its Reintroduction To Street And Track Duty
By Scott Parker
Photography by Scott Parker
Forth Gen Pontiac Formula Interior Redone Firebird Interior
Let's face it, our fourth-gens... 
   
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Forth Gen Pontiac Formula Interior Redone Firebird Interior
Let's face it, our fourth-gens aren't new anymore; matter of fact, far from it. The hatch and window glass doesn't seal well, if you're lucky the T-tops are leaking, the hood or hatch struts are shot, the armrest and the power window switches are broken.
New Headlights Hid Headlights
The stock bulbs on our '94... 
   
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New Headlights Hid Headlights
The stock bulbs on our '94 Formula paled in comparison to virtually every other car on the road, and it didn't take much to overdrive the headlights. Though we were tempted to do an HID conversion, adding Sylvania's Silverstar headlights seemed a nice compromise. The early fourth-gens use a sealed-beam style light with dual filaments for high and low beam. The H4666ST Silverstar has a color temperature of around 4000k, making it brighter and whiter than your standard halogen--making night driving safer.
Taking Out Old Headlight Stock Light Removed
To install it was just a matter... 
   
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Taking Out Old Headlight Stock Light Removed
To install it was just a matter of unscrewing the bezel,...
Hid Hightlight Installed Popped In New Headlight
...applying it to the new... 
   
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Hid Hightlight Installed Popped In New Headlight
...applying it to the new headlights and inserting it into the bucket.
Headlight Motor Gear New Brent Franker Headlight Motor Gears
While we were refurbishing... 
   
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Headlight Motor Gear New Brent Franker Headlight Motor Gears
While we were refurbishing the headlights, it seemed the perfect opportunity to upgrade the gears in the motor. I stumbled across Brent Franker's website and he was gracious enough to send me a set of his CNC-machined brass gears (he now machines them out of aluminum). They go for $45 a set, and are a great fix to the common headlight failure.
Stock Headlight Gear Chewed Up Headlight Motor Gear
Most often what happens is... 
   
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Stock Headlight Gear Chewed Up Headlight Motor Gear
Most often what happens is that the stock nylon gears get chewed up and worn (as seen here), and will no longer lock down into place. As the result, when you turn the lights off the bucket cycles down, and then pops back up again.
Removed Headlight Motor Headlight Motor In Vice
Removing the motor is pretty... 
   
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Removed Headlight Motor Headlight Motor In Vice
Removing the motor is pretty simple, it's just a matter of removing the trim piece around the bucket with a screwdriver, removing the nut that connects the arm to the motor, unplugging the motor, and loosening up a few 10mm nuts that secure it to the bracket. Then the cap (to the gear housing) gets pried off with a flat top screwdriver, the gear is removed, and the housing is treated to some fresh grease. Graphite grease is recommended.
Greased Brass Headlight Gear Brass Headlight Gear Installed
The brass gear is greased... 
   
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Greased Brass Headlight Gear Brass Headlight Gear Installed
The brass gear is greased as well, and the metal shaft is transferred over from the stock gear. The tabs slide into the holes on the face of the gear.
Applying Epoxy To Headlight Motor Cover Epoxy Must Sit For 24 Hours
The supplied epoxy is applied... 
   
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Applying Epoxy To Headlight Motor Cover Epoxy Must Sit For 24 Hours
The supplied epoxy is applied to the cover to reseal it, and it is left clamped in a vice for a few hours. The epoxy needs a full 24 hours to cure though, so don't expect to go jump in your car and pop the headlights on.

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