Any ideas or suggestions to mount a headlight in the higher position?
Thanks for any and all insight
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New boiler front? Maybe something is already available that saves hacking at this one.
A new boiler front is certainly a possibility; these can be found in Lionel's Replacement Parts (see Support on website), plus eBay is a good source of this kind of part. Don't shy away from Lionel Postwar pieces, as some of those smokebox fronts were actually well-modeled, are available and can be improved (better handrails, etc).
Of course, the diameter needs to match, and the mounting methods vary; often the headlight is not included. Depends. It's a journey, but I've done it more than once.
The advantage of attacking the original one is that it almost certainly will still mount the factory way, and is certainly the right size. I would recommend getting another one of the same part, if possible, in case you butcher it. Not criticism - just experience - as failure is always an option.
I made a 1615 switcher more Pennsy by moving the headlight to the proper position. Now this was a Basketcase rebuild, do I simply cut the headlight off, and used one from a junk 675 boiler front, drilled a hole for the light and held it on with JB Weld.
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Getting the OEM boiler front off of the smoke box looks to be a difficult task that could have ruinous consequences.
I would cutoff the existent headlight, fill the hole with J B Weld or an auto body filler, add a new headlight can where you want it, and relocate the existing light bulb.
