Casper97RS
10-22-2008, 07:13 AM
I picked up an extra set of headlights on Monday, and decided to start the project last night. I’m sure it’s been done many times, but I figured I’d throw in my own write-up.
I used some DupliColor primer/filler, some 400 grit sandpaper, and DupliColor Gunmetal Automotive Paint.
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00563.jpg
First step was to heat the headlight assembly in the oven. I checked around online, temps varied, so I just set it to 325, let it preheat, then stuck in 1 assembly at a time on a baking sheet. Getting the timing right on the first one was a bit tough. I left in for about 3 minutes, which actually made all the grey plastic backing a little too soft to work with. I let it cool a bit, then started working it apart.
Here are the original lights:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00553.jpg
After heating, I started working it apart with a couple flat head screwdrivers. The sealant they use in between is messy and really tough and sticky. I really had to take my time here. I found that by the time I worked some of it apart, it cooled too much. So I broke out a hairdryer, and the wifey sat there heating it as I went along. This worked great! I found it best to start near the top center of the assembly, and work my way to one end, then to the other, and then kept a screwdiver wedged in there while I flipped it over and worked on the bottom. There are a few clips along the way, I tried to be careful around those and only damaged one of them. The second light, I left in for barely 2 minutes in the oven, took it out and tried some prying, but it was a bit too tough. Stuck it in for another minute or so, and it was just right for working apart, gain with the help of the wife holding the blow dryer while I worked along the seam.
All apart now, here is the piece that will be painted – I have already removed it form the lens, and removed the 2 orange reflectors, and sanded with 400 grit paper:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00554.jpg
I then washed them off to remove all dust, and dried them thoroughly. Here they are primed:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00557.jpg
I let the primer dry for 30 minutes as directed before hitting it with paint. I shot it with a couple nice thin coats, just letting it get tacky in between coats. Here they are just after being painted:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00558.jpg
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00559.jpg
The I decided to replace the orange reflectors, and mocked them back up with the assembly. I haven’t finished sealing them, but here’s how they will look:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00560.jpg
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00561.jpg
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00562.jpg
I’m hoping to reseal them tonight. I figured I’d put the grey backing (which still has a lot of the hard silicone in the groove) back in the oven for a minute or 2 to soften it up again. I’ll take it out, add a bit of new silicone while it’s still warm, and press the 2 main pieces back together. I imagine I’ll have to get a couple big clamps as well to hold it together all around while it cools and hardens. Then, hopefully, get the bumper pulled this weekend and put them in. All depends on the weather though, since I don’t have a garage and will have to do the install outdoors. I’ll update more as I finish this project!
I used some DupliColor primer/filler, some 400 grit sandpaper, and DupliColor Gunmetal Automotive Paint.
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00563.jpg
First step was to heat the headlight assembly in the oven. I checked around online, temps varied, so I just set it to 325, let it preheat, then stuck in 1 assembly at a time on a baking sheet. Getting the timing right on the first one was a bit tough. I left in for about 3 minutes, which actually made all the grey plastic backing a little too soft to work with. I let it cool a bit, then started working it apart.
Here are the original lights:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00553.jpg
After heating, I started working it apart with a couple flat head screwdrivers. The sealant they use in between is messy and really tough and sticky. I really had to take my time here. I found that by the time I worked some of it apart, it cooled too much. So I broke out a hairdryer, and the wifey sat there heating it as I went along. This worked great! I found it best to start near the top center of the assembly, and work my way to one end, then to the other, and then kept a screwdiver wedged in there while I flipped it over and worked on the bottom. There are a few clips along the way, I tried to be careful around those and only damaged one of them. The second light, I left in for barely 2 minutes in the oven, took it out and tried some prying, but it was a bit too tough. Stuck it in for another minute or so, and it was just right for working apart, gain with the help of the wife holding the blow dryer while I worked along the seam.
All apart now, here is the piece that will be painted – I have already removed it form the lens, and removed the 2 orange reflectors, and sanded with 400 grit paper:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00554.jpg
I then washed them off to remove all dust, and dried them thoroughly. Here they are primed:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00557.jpg
I let the primer dry for 30 minutes as directed before hitting it with paint. I shot it with a couple nice thin coats, just letting it get tacky in between coats. Here they are just after being painted:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00558.jpg
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00559.jpg
The I decided to replace the orange reflectors, and mocked them back up with the assembly. I haven’t finished sealing them, but here’s how they will look:
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00560.jpg
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00561.jpg
http://i97.photobucket.com/albums/l227/casperitis/The%20ride/DSC00562.jpg
I’m hoping to reseal them tonight. I figured I’d put the grey backing (which still has a lot of the hard silicone in the groove) back in the oven for a minute or 2 to soften it up again. I’ll take it out, add a bit of new silicone while it’s still warm, and press the 2 main pieces back together. I imagine I’ll have to get a couple big clamps as well to hold it together all around while it cools and hardens. Then, hopefully, get the bumper pulled this weekend and put them in. All depends on the weather though, since I don’t have a garage and will have to do the install outdoors. I’ll update more as I finish this project!