Well I made a quick trip to Harbor Freight Tools and bought a crimping tool and yet more connectors.
I wish I could report success but after cutting two fingers and totally destroying three connectors I gave up using the tool. I managed to attach two connectors using a U-clamp and tightening the nut, however this not only crushed the wire but also the plastic collar. Surely there must be an easier way to connect these wires?
I cannot make any progress on reinstalling my headlamps until I get the new bulb socket installed.

David ('87 Wolfsburg - Headlampless)

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 From: David M <covrambles@YAHOO.COM>
To: vanagon@GERRY.VANAGON.COM
Sent: Sunday, October 6, 2013 1:27 PM
Subject: Headlamps, adjusters and connecting wires

Replacing my headlamp I managed to break all the adjusters on the headlamp and high-beam lamp.
Can someone explain to me why the screws for the high-beam unit wont screw
all the way out? Is there any way to get them out? I want to re-use the
plastic mounting thing but need to get the screw out so I can put a
washer and spring on each screw (my new adjuster design). I don't want
to remove the plastic things as if I do, I know they will break.
Also, removing the headlamp, I broke the bulb socket. I have a new socket and the wires all trimmed and ready to connect the new socket... but how do I join the bare wires together? The new socket came with 3 connectors
but no instructions on how to use. The holes are too small for the fat
wires on the van. I bought some 3M snap-in connectors on which the wire holes are bigger but cannot figure out how the wires attach to them. I threaded the
wires in and tried to clamp them in with pliers with all the force I
could muster but the wires still slide out. Do I need to buy a special
tool to use these? Thanks for any help.

I was hoping to get this job done this weekend but its eating up my time.

-David ('87 Wolfsburg)

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