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How much would one of these cost for either just the fiberglass casing or the whole unit? Where would be the best place to get it? Also where they all the same for any C4 or where there more specific ones like for 84-90 and 91-96?
By the plastic piece, I'm assuming you mean the fiberglass assembly tha holds the headlamp (and gets broken in a crash) these are the same, all years. All headlamps fit in any C4 as far a bolting up. There are two aluminum U-assemblies, both interchangeable, but you have to grind a piece out on the earlier ones to accept the later motors. There are three motors, but the 88 up two are only different as far as the wiring connector (two connectors vs one flat one, but the pins are different. The covers (top and bottom) are the same. Since the fiberglass piece is usually what gets broken (and were about $200 new), it's usually as cheap to buy a complete assembly. These usually go for about $150/side without the motor, and $250 with. You can find them anywhere corvette parts are sold (here, ebay, vette wrecking yds, etc)
Will the headlamp be the same on all 84-96? I'm just going to try to buy the whole headlight assembly from someone.
The difference between years is in the motor designs. I would go with a later year if possible to get a more reliable motor design. You might even find a set on craigslist and after I finish my fixed system, there should be a lot more available.
I had to buy the whole assembly when I had a light sheared off by a deer. (that's all it did luckily)
I picked one up on Ebay for not too much. But be careful on there, some of those yahoos go in and try to get you overbid. Almost happened to me.
Also if you have to get it painted, it won't match. I had mine painted by the exact code and it didn't match because even a white car like mine will fade and the yahoos couldn't match it up, even though they had the old lid to use to go off of.