This
is the procedure I used to clear the corners on my 2000 Mustang.
This involves cutting into the headlight, removing the reflector,
and bonding the headlight back together. These instructions come
together after struggling with the first headlight, and refining
the process for the second one.
Preparation:
Workspace: A bit dusty during cutting, I just used a chair in my puny garage.
Tools: Dremel Tool
(or similar cutting tool), safety glasses (not kidding),
needle nose pliers, J-B Weld
, spreading tool (I used a dental tool from the flea
market - $1), clamps, compressed air, a couple of towels.
Procedure:
(Click
thumbnail for full-sized image) |
Un-clear
corners: |
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Removal
of headlight
Start by removing the headlight. Lift hood and pull the two
pins that hold the headlight in place. Once removed, you can
un-clip the two wire harnesses to go to the bulbs. |
Removing the pins |
Wire harness |
|
Getting
Ready to Cut
Remove the bulbs from the fixture and stuff a rag inside the
side marker side. This will minimize the amount of dust and
debris that gets inside of the fixture. There will still be
some that gets inside, however. Also, stuff a rag in the bulb
holes for added protection.
Next,
ready your dremel tool by putting on a good cutting blade.
I used a "saw-tooth" type blade (about $10 at OSH)
because it seemed to cut better than the disc, and made the
hole a bit thinner. Although it seems geeky, I must encourage
safety glasses. There is stuff flying all over, and the likelyhood
of the blade breaking is good. Do yourself a favor - you might
need that eye later :-) |
Towel inside fixture |
Tools for the job |
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Making
the Cut
Now it is time to cut. First, cut the top of the light (top
if it was still in your car). Follow the rubber strip as closely
as possible. Click on the pic to see the line to follow. The
depth of the cut is about 3/4 of the 1 1/4" blade I used.
Cut slowly and check your progress often. You will be cutting
through the grey plastic outside, then the clear plastic.
If you see sparks when you are cutting, you have gone far
enough. The sparks are from the metallic reflector in the
back of the light.
Next,
cut the side of the fixture. Use the brass torx head screw
as your guide. Make the cut just inside of that screw. Do
not go as deep as the top cut - there is less material here.
Finally,
make the cut on the bottom of the fixture. There is a little
valley between the clear part and the grey plastic portion.
Make your cut as close to the clear plastic as possible. You
will loose a bit of the grey plastic, but you will be able
to fill it in with JB Weld. Go as deep as on the top side
of the fixture.
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Cutting the top |
Cutting the side (end) |
Cutting the bottom |
|
Removing
the reflector
Now that the cut is made, you can pry open the lens. If it
does not open easily, there is probably some of the grey plastic
that is holding it. Another hold-up may be the metallic reflector
catching the end of the grey plastic. If that is the case,
just bend gently until it comes out. Be careful if you insert
a screwdriver or blade - it scratches easily.
Next,
reach in with the needle nose pliers and liberate the orange
reflector. It may put up a bit of a fight, as it is lightly
bonded to the clear lens. Wiggle it around a bit and it will
slide out. Pull it out gently so that you don't scratch the
lens or metallic reflector |
Prying open the lens |
Removing the reflector |
The reason we are doing this |
|
Cleaning
up the mess
This step probably was the most time consuming - next to waiting
for the JB Weld to cure. Lots of junk gets into the fixture
during the cutting process. I experimented with a vacuum with
a straw taped to the end. Worked, was painfully slow. Settled
on compressed air.
First,
use a small blade or the Dremel with a grinder to remove any
annoying plastic shards around your cuts. Next, remove the
rags that were put into the openings, and the one inside the
fixture. With the compressed air, blow through the bulb openings
while prying out on the lens opening. Repeat. Again. And again.
You get the picture. Be careful in the headlight opening -
there is a little "hood" that is pretty flimsy.
Blow again. |
Blowing the gunk out |
My fancy compressed air unit |
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Putting
it back together
Once the fixture is as clean as possible, use some clamps
and pieces of a rag for protection to pinch the fixture together.
Focus on the top and bottom first and make sure you have sufficiently
closed it up.
Next,
mix up the JB Weld. I first tried with two-part epoxy, but
found that to be way too runny. The JB Weld was a good consistency
and did not leak into the fixture. Remember, only mix up a
little at a time. The JB Weld sets up in about 4 minutes.
Spread
the mixture on the top part of the fixture. Smooth it out
with your spreading tool. You can also wipe off any extra
with a rag if you are quick.
Repeat
on the bottom of the fixture. Once the top and bottom is done,
give it a bit to set up - I took a beer break at this point.
Once
your beer is finished, you can move the clamps to do the end
piece. I found it easy to move the clamps to the side, apply
the JB Weld, then move the clamps as shown in the lower pic
for the best pressure. The end piece wants to flex outwards.
Final
thought on sealing - do a good job. I am sure it is impossible
to seal it as well as the factory did, but you want to aim
for that. Washing and rain will be the enemy here. Take your
time and be thorough. |
Clamping the fixture |
JB Weld and "the tool" |
Spreading on the JB Weld
|
Smoothing it out |
Clamping the end for sealing |
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Finishing
up
Once the JB Weld has hardened, you can use the Dremel again
to grind down any rough spots(be sure to stuff your rags back
in the bulb openings!). If you don't wait for the JB to harden,
you will make a mess. Be patient.
Once
you are happy with the finish, replace the bulbs and re-install
into your Stang.
A
note on the side-marker bulb - it is amber. It is supposed
to be amber. If you put something other than that in there,
you will probably be ticket bait. I read that Phillips is
coming out with a bulb this fall that has a mirror finish
when off, but glows amber when lit. That would be a nice addition.
I will update when I find out some information. |
Grinding the finish |
The end result! |
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Its Done!
All
in all, I think this was a nice addition. It has a cleaner look,
but it is not something that jumps out and screams "MOD!!".
I think the addition of a different bulb will be nice. I will also
be watching during rains to see if I get any leakage. I did not
get any leakage during my first wash, but I don't do high pressure
water.
found
@ http://www.fnsweet.com
By: Kev
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