Adjusting headlight washer jets on older Porsche models like the 944, 928, and air-cooled 911 can be frustrating. These jets are often incredibly tight, making manual adjustments nearly impossible without risking damage. This DIY guide provides a simple solution: crafting a custom car headlight aiming tool using readily available materials. This tool replicates the functionality of the specialized 9135 aiming tool, offering a cost-effective alternative for enthusiasts.
The core of this DIY tool lies in selecting the correct aluminum tubing. A 10mm outer diameter (O.D.) and 8mm inner diameter (I.D.) tube provides the perfect 1mm wall thickness to snugly fit over the washer jet and slide into its designated slot. This tubing is readily available online; for instance, a length sufficient for six tools can be purchased for under $7 on Amazon. The leverage provided by a 4-5 inch tube makes adjusting the jets surprisingly easy.
Crafting the Car Headlight Aiming Tool
To create the tool, begin with a 4-inch section of the 10mm O.D. x 8mm I.D. aluminum tubing. Using a Dremel equipped with a metal cut-off wheel, make three precise cuts to shape the end of the tube into a two-pronged fork.
- First Cut: Make a 7mm deep cut down the end of the tube, positioned approximately 3mm from one edge.
- Second Cut: Cut across the tube 7mm from the end, leaving a smaller “tongue” section standing.
- Third Cut: Create a 1-1.5mm slot down the center of the tongue, dividing it into two prongs.
After cutting, smooth all sharp edges with a file. Test-fit the tool on a washer jet and make any necessary adjustments with the file for optimal fit.
Adding a Handle for Leverage
While not essential, a handle significantly enhances leverage and control. A T-handle can be welded onto the tube for a professional finish. However, for those without welding equipment, alternative solutions exist. A collar lock can function as a handle, or a long bolt inserted through a drilled hole can provide ample leverage. In a pinch, pliers can be used on the tube itself, but exercise caution to avoid damaging the tubing.
This DIY car headlight aiming tool provides a simple yet effective solution for a common problem faced by classic car owners. With minimal investment and effort, you can achieve precise headlight washer jet adjustments, ensuring optimal performance and visibility. Remember to prioritize safety and take your time to ensure accurate cuts and smooth finishes for a durable and functional tool.
