Headlight Assembly Lens Replacement



Headlight Assembly Lens Replacement

Postby Indycars » September 24th, 2012, 11:06 am


A few weeks ago I went to Pull-A-Part salvage yard , I needed both headlight assemblies. I
found one , it had a near perfect lens, but a busted case. I grabbed it thinking it would be
easy to change the lens.

Leaving Pull-A-Part I went home a different direction because of traffic and stumbled
across LKQ Self Service Auto Parts. I wasn’t even sure what they meant by Self Service,
so I Googled it found out its another salvage yard like Pull-A-Part.

Last Friday I went to LKQ to get two more headlight assemblies, mine were still busted
from the accident I had last July. They had what I needed, but as you might expect
the lens were very hazy. So I would replace one with the good lens I already had and
polish the other one.

I’m thinking I can just pull the 5 little stainless steel clips and pop the lens off.
No not going to happen, it’s not nearly that easy. I found out you have to
heat them to 200° F for 5-6 minutes so the adhesive will loosen up and you can
pry them apart. Sometimes it takes 2-3 trips to the oven before you can get them
completely apart.

The seal must be important to keep any moisture away from the lamps. So I
scrapped some off the extra parts I had and used it to make sure I had a good seal.

Pic01_3216.jpg
Pic02_3220.jpg


Once I was happy with the adhesive, I put the lens on and stuck it in the oven
again. This time I used 225°F, you have a limited time to work before it’s too
cool again. After 3 times in the oven I decided to use some local heating by
using the halogen lamps I keep in the garage. I used some C-Clamps to apply
a continuous pressure to help push the lens all the way on.

Pic03_3228.jpg


You can get the plastic too hot as you can see below.

Pic04_3232.jpg


The other side required polishing to remove the oxidation. I used some soapy
water and 1000, 2000 and 2500 grit Wet-or-Dry sand paper. Then I got out my
air operated die grinder so I could control the speed and soft cloth type wheel
with jeweler’s rouge and immediately you could see the shine and clarity of
the lens come back. I finished it off with some wax. Below you can see the results.

Pic05_3237.jpg



You do not have the required permissions to view the files attached to this post.
Rick
Too much is just enough!!!

- Check Out My Dart SHP Engine Project: viewtopic.php?f=69&t=3814
- Need a Dynamic Compression Ratio Calculator: viewtopic.php?f=99&t=4458
Indycars

User avatar
Forum Admin
Forum Admin
 
Posts: 4424
Joined: May 25th, 2010, 8:58 am
Location: Yukon, OK

Return to Interiors/trim/dashes etc.

Who is online

Users browsing this forum: No registered users and 1 guest

cron