Hey, I've got new seals and dust covers for my headlight actuators and was wondering if anyone out there has any advice on going about replacing the old ones  Do I have to take the actuators off? Any advice would much appreciated

You can replace the seals without removing the actuators, BUT...it's a real pita to do it that way.
It's best to take the actuators off and do the seals that way, and believe it or not, it's actually quicker, too!
The accordion dust covers are held on by a small retainer that needs to be bent open to get it off. (You'll be able to see what I mean once you get the actuators off)That's really the hardest part of the job...taking the retainer off, and crimping it back on. The actual seal replacement is fairly simple, and self-explanatory once you get to them. I don't remember anyone here posting any pics of the seal retainers, but someone may have their actuators off right now, and might be able to post a pic.

I wound up taking the actuators off to replace the seals and dust covers, ti would have been impossible to do it with them in place.  In the process I had to remove my vacuum relays so decided to bench test them with a vacuum gauge and of course they are also bad.  I don't suppose anyone makes a rebuild kit for the actuator relays Seems like when you own an older vette, theres always something that needs work on

No rebuild kits for the actuators that I know of. There are a few places that can rebuild them, but new ones are only around $40 or so.
I did dis-assemble both of mine(originals) a long time ago. There are a couple of o-ring seals on the shaft that slides up/down to direct the vac. to the different ports...pretty simple device. The problem is getting the top cover crimped back on to where it won't leak, without tearing the top diaphragm.
Of course...where would you get the parts to fix it if you do? I found out that new relays come with all that stuff, and they're already assembled, and ready to install!
Best to just replace them.

 
Thanks Joel   That's what I figured also, but I wanted to know if anyone out there had come up with some way or a kit to fix them.  I will probably live with it the way it is for awhile since my lights pop up and go down just fine while the car is running.  It just won't hold vacuum in the reservior is all.

John