Decided to have a semi day at work & field e-mails whilst I worked out how to do the headlights...

followed this method which went OK when I read it properly...

http://www.caterhamr500.co.uk/2014/02/build-day-four-headlight-and-indicator.html

first attempt I did all the wiring & was very pleased with myself & then I noticed the nutindicator housing & bracket sitting there looking at me... had to take it all apart again.... how I laughed.

Couple of things I did that weren't in the details above:

I Sprayed rubber lubricant down the floppy tube that comes with the headlight assembly. This made it much easier to push the green wire through with all the other wires. I used shrink wrap to tidy up the ends of the floppy tube, this made it a lot easier to push through the holes in the headlight bracket & it will go through the rubber grommet in the chassis with no issues (I tested it...).

Future issues... the green wire is quite short so I'll probably need to extend it when it comes to electrics time... All the other wires are quite long. In the manual its says 'pull the wires into the headlight to get the correct length' LOL, I'll eat my hat if that works but I'll give it a try when I get the lights fitted. as they are soaked in lubricant it might work but I'm not hopeful.

I've never used shrink tube before... its great! tested it out on a few random things. Heated it up with a mini propane powered soldering iron (the top bit comes off & it turns into a mini blow torch). Very happy with this bit of kit & my new shrink tubing skills... If in doubt it will be shrink wrapped...

I did destroy the soft grommet thing on one of the green wires (as it went in & out of the black tube a few times). Hopefully this is just a seal & i can drop some silicone in or something. Seems too soft to be anything structural in the socket.... hope not anyway.

Next project: finish off all the front suspension & headlights. I'm a bit more confident about this as I'm pretty much half way there really. & it means I can put my head in the sand re the 'elephant in the room'... who needs an engine when you have other things to do...