f18delta -
The headlight lens seals that I bought for my '54 were a little long. I had to cut them to fit. They have a wire insert(don't cut the wire) and have a little flap similar to your description. The edge of the headlight bezel sits in the flap. When the bezel is installed, the seal fits tightly between the bezel and the headlight retainer. And yes, the wire clips are difficult to attach, as if the diameter of the seal is too large. You may need to slightly bend the clips to improve the fit, especially the top clip that fits into the slot in the headlight bucket. Here are reproduction seals and clips installed in my '54 bezels:
> Seals installed - inside view You can see the flap on the cutoff pieces.
> Seals installed - outside viewMy '54 did not have the original seals, so I don't know if the reproductions are larger. Denny Graham says that reproduction headlight lens seals are larger diameter than the originals, as you also say.
> Denny's discussion about the seals. NOTE: The forum software ate Denny's text so they look like blank posts. But you can still read them by clicking on "Quick Quote" under the blank posts.> Denny's "Headlight" albumFYI - bezels were different on some pre-war Chevrolet passenger cars, and maybe trucks. There was a mounting tab attached to the top of the bezel. The top wire retainer clip serves as the mounting tab on later models.
> 1940 Special de Luxe Sport Sedan The "top" is actually on the right. Not sure if the wire retainers are installed correctly.
- Lonnie