DIY Headlight Washer Aiming Tool 9135

Product Instructions, Repair Procedures, and Other Technical Downloads
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Tom
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I recently made a tool to aim the headlights washer jets on the 944, 928, air-cooled 911's, etc. -- i.e.., on any car that used the old 9135 Aiming tool. Those washer jets are super tight and virtually impossible to aim by hand, and using pliers and similar tools risk damaging the plastic. This tool is based partly on pictures I've seen online of the factory tool, partly on trial and error, and partly with a view to making it an easy DIY project. The key is getting the right size tube -- 10mm outside diameter and 8mm inside, giving it a 1mm wall. That's the perfect size to slip over the jet and into the jet's slot. I got enough for 6 tools for $6.99 on Amazon. It's amazing how easy the jets move with 4 or 5 inches of leverage on your side.
dim1.pdf
dim2.pdf





Starting with about 4" of aluminum tube,10mm O.D., and 8mm I.D., use a Dremel with metal cut off wheel to create the two-prong, end-shape shown. Technical drawings with dimensions are available for download above, but it really comes down to 3 cuts with the Dremel. First cut down the end of the tube (about 7mm deep and 3mm away from one edge of the tube). Then cut the tube 7mm from the end, leaving the smaller tongue section of tube left standing. Then cut a 1 to 1.5mm slot down the center of the tongue to create the two prongs shown in the picture. File the edges so nothing is sharp, and adjust as needed with a file after test-fitting the tool. I welded on a t-handle using left over tubing (always looking for TIG practice), but that's not necessary if you're not a welder. If you need more leverage to rotate the jet, you can add a collar lock to serve as a handle, or drill and hole and use a long bolt in lieu of my T-handle (or use pliers on the tube if you're an animal :lol: ).






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