This weekend I attacked the headlight brackets which have been bugging me for a while! The brackets are fine but the bond straps aren't right.
What was on the jeep was a very efficient modification which I think is commonly found on French Army jeeps, however it looks quite different to WW2 spec. The late war Willys should have grounding wires not bond straps on the brackets. The "French" mods look like this:

Old Brackets & bond strapsOld Bond Strap

At Stoneleigh Militaria I collected a set of WOF (Willys Overland France) headlight brackets from Tony Sudds (TS Autos). I re-painted them in my favourite flat OD from Dallas Autos (aerosol spray) and drilled 4mm hole on the inner side of each one:

New Headlight Brackets TS AutosNew Brackets Drilled & painted

I've looked all over and asked all the usual suppliers if they had the bond wires, no luck and they weren't included in the bond strap kit that I bought last year. So no option but to create a facsimile of them. I used 6 inches of copper core wire (I only had red/white in the tin!) and vintage car type connectors, large at one end and small at the other.

New bond wires

I wasn't sure if the bond wires were a set colour so I painted them black (Tamiya waterbased flat black model paint), the photos I've seen show a variety of colours - black will do for me.

When I came to fit the new brackets I found some really nice big star washers on the fixing bolts (which were all imperial sizes) so I cleaned them up and used them again. I made sure all the contact surfaces were sanded to bright metal to help the grounding and then fitted the new brackets. The big ends of the bond wires were fitted between the bracket and the grill and the small ends fixed with a machine screw and small star washer to the hole on the bracket.

Old & New paintedNew in place 1New in place 2New in Place 3

Looks pretty good for now, maybe the real stuff will turn up one day! I was totally amazed when I turned on the headlights and they still worked ;)

More photos at:

http://www.surfacezero.com/g503/showgallery.php?cat=500&ppuser=498

For all your Jeep and Dodge needs:

http://dallasautoparts.com/index.htm