Many of us non-mechanics still like to tinker, but hesitate to do so without some step-by-step instructions. Here's a fun 1-day project that I borrowed from another forum a few years back, and just did on my Jag.

Tried to make this in Keynote slides. Lets see if it turns out:

Caution: Don't mask the chrome as shown. The tape may damage the chrome surface. I'll update or remove the thread as I get more info.

 

Nice one MD, thanks for taking the time to share

 

I'm sure it's all good and fine but I vowed a long time ago to never attempt a mod that requires putting some of my car in an oven.
Would love to see this on a red XK however.

 

Buddy of mine warpped the tail lights on his stang doin that!

 

I checked it frequently, about every 5 min, and 15 seemed to be about what it took. I was paranoid about warping them, too, but I don't think it even came close. Very important, ahem... men... To preheat your oven first. The element stays on during the preheat process, and you don't want your expensive headlamp in there while the preheat process is going on.

I agree it would look so cool on a red car. I mostly just wanted to get rid of the ugly orange reflector on the side that broke up my sleek, black line. I painted it as an afterthought.

 

My wife already thinks I'm certifiable. Headlights in the oven would most definitely initiate the phone call.

 

because the headlights are projectors, couldnt you paint the pointless chrome below the projector housing? I did that on my Avalanche, and I think it looks way better. I hate chrome.

 

How are the headlights holding up? I'd like to do something similar but afraid the damage them in the oven. Any other way to do it without baking?

 

The baking is to loosen the glue. I don't see any other way without even more risk.

 

The headlights look great. No problems. I'm glad to be rid of that ugly orange reflector. The baking is not too radical. If you think about it, 150-60 deg F is not too terribly hot. Just warm enough to need a thin pair of garden gloves when handling. A heat gun would be way too hot, I think.

 

Thank you, was the glue messy and what did you use to reseal? Any reason you chose not to paint any of the chrome? And were yours adaptive headlights?

Sorry for so many questions. I just pulled one of the assemblies out and it looks different from yours. There are 2 metal boxes, one is the ballast and the other is the AFS module, marked with HANDLE WITH CARE. Do yours have those? If so did you leave them on? I didn't see any mention of it. TIA!

Another difference is I have 5 bulbs, but you only show removing 2. Any reason why you only removed 2 and not 5?

 

1) The "glue", when warm and sufficiently soft, is like bubble gum. As I stretched it apart I used scissors to cut the sticky strands, which recoiled back in place, leaving the gummy residue on both sides. This quickly rehardens as it cools.

I reapproximated the lens cover and reheated it to get them to stick again. I didn't have to add any more of the adhesive during the reapproximation process but I'm told any auto supply store would carry it.

2) I personally like the chrome. If I had something other than a black car I might feel differently.

3) They are self-leveling but not the kind that turn when you're turning corners.

*edit: sorry, I just saw the rest of your post. I don't know much about automotive differences, I just take things apart and put them back together again. Usually with an extra screw left over. I wouldn't want to advise you; I'm just saying what I did.

 

Did you remove the metal ballast? I would think it would get really hot and damage the electronics?

How about the other 3 bulbs? You said to remove 2 but there are 5 total.

 

I'll have to double check on the bulb situation when I get back home. I was concerned about the bulbs only insofar as the risk of cracking one of them during the heating/cooling process. I don't think I removed the electronic component.

*edit: I think the two bulbs have to be removed to separate the lens housing from the back assembly, while the high intensity lamps stayed with the back assembly. I removed the round access covers to better circulate the warm air throughout. As for the electronics, I'd be surprised if 160 deg F is even outside their normal operating temp range. I bet the lamp itself runs hotter than that. But I really don't know.

 

I took the plunge and decided to take one apart...via a hair dryer and panel trim removal tools. Hair dryer was hot enough to soften the seal, but what a mess!!! Hopefully I can clean up the edge of the cover with some heat.

By the way the reflector assembly was a real challenge to remove so hopefully it will go back in without too much of a struggle as I won't want to scrape the new paint

Will tape and paint the insert tomorrow, fingers crossed, as soon as I settle on what parts to paint. And if all goes well, will tackle the passenger side.

 

Good to know. Looking forward to seeing your results.

 

Second headlight came apart in less than a minute and no mess. This time I left it out in the direct sun for a few hours and used the hair dryer to warm up the seal a bit more. Came right apart so I can see how the oven would have been easier for the first one but it turns out the sun does the same thing with a bit less heat.

I have only painted one so far and will wait until it is finished and put back together before I paint the second one.

I will post pics.

 

I have run into a bit of a problem. The painter's masking tape has removed the chrome finish. Any idea how to mask them off so the chrome does not come off to?

 

Oh no! Are you going to have to touch it up? Others might be able to chime in here, but I always pull masking tape off shortly after I paint, before it's dry. This prevents ripping the fresh layer of paint off when I take the tape away (especially latex paint on projects around the house), but I guess it also keeps the tape from bonding too much with the surface below as well. Maybe try a different brand tape. I just picked up a roll of 3M "Scotch Blue" for delicate surfaces the other day (although that's not what I used for this project).

 

Unfortunately it is not repairable, the chrome is a PVD coating. The only solution is to paint it too which is going to change the look I was going for. The tape was the blue kind but it did sit on there for a few days because the spray I used left a couple of drops and I had to wait before I could sand and re spray. I'm going to buy another type of tape I guess.