E-code Headlight leaks water

[Doyt W. Echelberger]

I have the quad rectangular headlight system (E-code lamps) from Nick
Lawrence's 1985 5000 on my 87 5ktq, and the outboard low beam on the driver
side leaks water somewhere. The glass units were new, from Daniel Stern.
Outboards are Stanley-made 165mm x 100mm (6.5" x 4") H4 high/low beam
headlamps). Inboard high beams are Cibie.

Haven't found the leak, and only one of the 4 lamps is leaking. The
reflector chamber ends up with about a quarter inch of water after every
big rain. Otherwise, the quad lights, properly relayed with heavy wire,
have been incredible. Stern sent me some very useful stuff.

Trying the obvious, I took off the rubber lamp shield that protects the
replaceable bulb on the back of the lamp. I removed the bulb and vacuumed
out the water. Then I used a hair dryer to dry up any remaining moisture
inside the reflector. I blew the heated air into the bulb opening, and also
onto the front of the unit, to heat the glass lens. I cleaned up the
sealing surfaces of the rubber shield on the back of the unit, replaced the
bulb and shield, and then I covered all the wire connections with liquid
electrical tape.

It rained for the past few days, and the water is back in the reflector space.

I think I'll remove the entire lamp and bring it into the house and test it
in a basin of water, to see if the water is coming in though the seal
between the reflector and the front lens. I'm confident that the rubber
shield around the replaceable bulb was tight and covered with liquid
electrical tape, so I suspect another source for the leak. But I'm only
guessing.

If anyone has any experience with such leaking quad E-codes, and some
ideas, I'll be very appreciative. Nothing like a BTDT. Hope to hear how you
did it.

Doyt Echelberger
87 5ktq with retro quad E-codes
Ohio   USA