It should be pretty straight forward. You will need to drill out the aluminum rivets holding the light covers on. When drilling out a pop rivets it is a good practice to use a punch to hammer out the hard steel shaft in the center of the rivet. They use a drill that is about the size of the rivet hole and drill carefully until the head pops off. Then push the rest of the rivet through.
Once the cover is off you will see that the body is molded to the right shape to hold the lights. Before you go any further you should hold up the clear lens cover to see if the holes match up to the holes that are already drilled... they most likely wont so you should do a fiberglass and gel-coat repair to the holes. The next step is to drill out the holes for the lights. you will need a hole saw for each hole size. The location of the holes should be marked. Once you have drilled the three holes you can install the lights. They get installed from the front and then there is a bracket that is attached to the back to hold them in. On my car the blinkers were held in place with silicone, so I don't know if there should have been a bracket to hold them. Once the lights are installed you need to fit the clear lenses in place and drill them out. when you install the bolts and nuts that hold the lenses in place be sure to use the small plastic grommets in each hole to prevent the plastic from cracking.
Next you need to install the wiring harness for the nose. Stand the nose up vertically or turn it upside down to get access to the bottom. Start by attaching the wires to each of the lights. Then rout the wiring harness using the tie-wraps to the attachment points that are on the bottom of the nose. the wire harness routs to the area of the left front wheel. You will need to have about 12" of extra wire at the end to give you room to plug it into the car.
I don't know if your car will have the wiring on the chassis already in place or if you will have to install it. I can see from the pictures of the interior of your car in the registry (chassis number 583) that the switches are in place, but I cant see if the wiring is in place. If the chassis wiring is in place there will be a plug in the area of the front left wheel. If the harness isn't there you will need to attach it to the switches under the dash. Here is a picture of what the area looks like when the upper body is removed. you can see the plug and wiring mounted to the chassis near the left wheel.
Let me know if you have any questions. Also, when the car arrives we can "Facetime" and I can walk you through it.
Can anyone send pictures of the underside of the front shell showing the direction and mounting points for the front lights including slack for the plugging in of the light harness?
I checked my pictures and I don't have any that show the routing. The key aspect of the routing is the length of the plug hanging down from the nose. you want this to be long enough to allow you to plug it in while mounting the nose, but short enough so that the tire can't come in contact with it while turning. I would recommend taking the nose off and then taking some pictures (looking down on the wheel) showing the wheel position in a full left hand turn. Then I would put the nose on and jack up the car and remove the front right wheel. Then you have the access to adjust the wire harness to a good length that will not contact the tire. You may have to do a little adjusting to get it right.
Also see some extra pieces and not exactly sure where they go....
The Red wire is a jumper wire that is used on the back of the switches. Here is a picture showing how it is used.
I believe the black rings are seals that are used on each of the holes for the headlights.
I believe the springs are used to provide spring tension on each of the bolts that attaches the headlight to the back up plate. Do you have a picture of all of the parts that came in the headlight kit?
Here is a diagram I made showing how the headlight switch wiring is in my car. Note that this is not an official Radical document, it is how my car was wired from the factory....and it worked.
There are 3 lights on each side. All plugged in and 4 indicator wires come off near the harness end.
when I plug in main plug but not 4 indicator wires, indicator switch works and I get slow blink one direction and fast blink on the other. Dip/main beam switch does nothing, Headlight on switch turns small light on in main large lights. Fog light switch does nothing.
so largest lights come on but only small bulb. Fog lights nothing. Indicators seem to work.
There are 3 lights on each side. All plugged in and 4 indicator wires come off near the harness end.
when I plug in main plug but not 4 indicator wires, indicator switch works and I get slow blink one direction and fast blink on the other. Dip/main beam switch does nothing, Headlight on switch turns small light on in main large lights. Fog light switch does nothing.
so largest lights come on but only small bulb. Fog lights nothing. Indicators seem to work.
Those pictures help a lot. It sounds like you need to install that jumper wire between the "Headlight on" switch and the "Dip/Main Beam" switch as show in the wiring diagram and then everything should work. Regarding the extra wires. Now that I have thought about it a little more I believe I remember them being just "coiled and stowed" under the hood. I think they are for side markers on road legal cars. See the attached picture of chassis 547, which was road legal in the UK, and you can see where the side markers are.
On the side with the fast blinking, check your tail lights to see if the turn signal bulb is burnt out, or if the wire is disconnected. Regarding the fog light switch... That switch controls one of the red tail lights and doesn't do anything up front.
When you install the main (larger) beams you will be pop riveting the round ring to the nose of the car. If you look at the picture I posted of my installed headlights you will see that there are two pop rivets on the sides of the main beams. Then you will attach the adjuster screws to those round plates. Then you put the springs on those adjuster screws....and then attach the main beam to the adjuster screws. The springs and adjuster screws allow you to adjust the angle of the beam. When you install the upper light you will slide the light in from the front and then put the two aluminum brackets on the inside of the nose. Then you put the screws through the aluminum bracket and screw them into the back of the lights. The turn signals on my car were just held in place with some silicone caulk. I don't know if that is how they should be installed, but that is how they were on my car.
