Joined
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547 Posts
Hey guys this is my 1st proper project so go easy on me! 
Thought id finaly open up my spare headlamps i recently got off a mate and begin refurb and retrofit!
Been a bit busy today so ive only cracked them open so far.. took about an hour
So 1st thing to do is remove all the little bits, rubber seals, brass clip etc...
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Next thing to do is seperate the lenses from the housings!
I preheated the oven to about 180 degrees to begin with then popped the 1st one in
![]()
Left it in for about 5 mins and pulled it out. Now begins the messy bit. I used a butter knife and a flat head driver (WARNING! if you ever undertake such a project do not use the misses best knifes!) to seperate the lense and housing. The key here is to seperate the lense evenly orelse you will probly crack or break it so the way i did it was start at the top centre
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The sealant they use is realy tough and go's hard quite quickly so bein quick is key otherwise, back in the oven!
As it starts to come away work the knife around the edges whilst gently pulling it away from the housing
![]()
Eventualy it will peel away from the hard to get to places, then with the lense facing down cut away the last bit of sealer along the bottom!
![]()
And this is the two seperated
![]()
Now that the housing is split its time to remove the projector surround from the lense.
Its only held in with 1 screw
![]()
A bit of a tug pulls it right outa there
![]()
Then to remove the 2 bits off the surround.
Theres the sidelight bulb lense and a little chrome piece which sits under the low beam projector
![]()
The sidelight lense is held on by 2 screws
![]()
and the chrome bit is held on by a 3 bendable tabs (not very clear in pic)
![]()
Once everything is off
![]()
![]()
Chrome has flaked away a bit round the reflector bowl, not realy bothered though, should clean up easy enough!
![]()
Thought id finaly open up my spare headlamps i recently got off a mate and begin refurb and retrofit!
Been a bit busy today so ive only cracked them open so far.. took about an hour
So 1st thing to do is remove all the little bits, rubber seals, brass clip etc...
Next thing to do is seperate the lenses from the housings!
I preheated the oven to about 180 degrees to begin with then popped the 1st one in
Left it in for about 5 mins and pulled it out. Now begins the messy bit. I used a butter knife and a flat head driver (WARNING! if you ever undertake such a project do not use the misses best knifes!) to seperate the lense and housing. The key here is to seperate the lense evenly orelse you will probly crack or break it so the way i did it was start at the top centre
The sealant they use is realy tough and go's hard quite quickly so bein quick is key otherwise, back in the oven!
As it starts to come away work the knife around the edges whilst gently pulling it away from the housing
Eventualy it will peel away from the hard to get to places, then with the lense facing down cut away the last bit of sealer along the bottom!
And this is the two seperated
Now that the housing is split its time to remove the projector surround from the lense.
Its only held in with 1 screw
A bit of a tug pulls it right outa there
Then to remove the 2 bits off the surround.
Theres the sidelight bulb lense and a little chrome piece which sits under the low beam projector
The sidelight lense is held on by 2 screws
and the chrome bit is held on by a 3 bendable tabs (not very clear in pic)
Once everything is off
Chrome has flaked away a bit round the reflector bowl, not realy bothered though, should clean up easy enough!
