Abstract: A headlamp capsule with a formed lug seal is disclosed. The base of the capsule includes an intermediate wall separating a plug chamber and a lamp chamber. An electrical lug connection is formed in the intermediate wall to couple the two chambers. A walled structure is formed that includes positioning features to align and hold the lug. The accuracy of lug location may thereby be improved. The wall structure also provides a reservoir to hold a liquid sealant around the lug. The reservoir may be made to form with the lug, and thereby substantially reduce the amount of the sealant needed for a durable seal.