Alexei Volkov
Sealed headlights can be opened using a variety of methods, including baking, cutting, and heat guns. The most suitable method depends on the type of sealant used, which is typically either Butyl or Permaseal. Butyl is a rubbery and soft sealant that can be softened with heat, whereas Permaseal is hard and won't indent easily, so it requires the use of a cutting method. To identify the type of sealant, you can try pressing a flathead screwdriver or pick tool into the edge of the lens where it meets the housing. If the sealant is soft and indentable, it is likely Butyl, and you can use the baking method. If it is hard and difficult to indent, it is likely Permaseal, and you should use the cutting method. It is recommended to try the baking method first, as it is cleaner and allows for a better reseal. However, if the housing does not separate after baking, switch to the cutting method to avoid applying excessive force and damaging the housing.
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What You'll Learn
Baking the headlight in an oven
Baking your headlights is a great way to modify them for a retrofit, add LEDs, paint the chrome, or just reseal them to keep out moisture. Here is a step-by-step guide on how to do it:
Preparation:
Before you start, ensure you have the necessary tools and safety equipment. You will need a flat-headed screwdriver, a set of pliers, clamps, microfiber towels, oven mitts or heavy-duty gloves, and, of course, an oven or a heat gun. It is recommended to wear disposable work gloves and an old shirt to avoid getting sealant on your skin and clothes. You may also want to wear heat-resistant gloves underneath for added protection.
Removing the Headlights:
Open your vehicle's hood by locating the lever or button inside your car, on the driver's side. Pull the lever or push the button until you hear the hood click open. Completely lift the hood to keep it from falling while you work. Consult your vehicle's manual if you need assistance with this step.
Now, remove the headlights from your car. You may need to remove the bumper by locating screws and clips at the top, bottom, and sides. Disconnect the headlight harness. Collect all the screws and bolts and place them in a plastic bag to avoid losing them. Ensure your headlights are thoroughly cleaned before proceeding.
Baking the Headlights:
Preheat your oven to a temperature between 200-250 °F (93-121 °C). It is important to ensure your oven is large enough so that the headlights do not touch the sides, as this could cause melting. Place a cookie sheet or a layer of aluminum foil inside, and if desired, put a wet cardboard or towel on top to prevent the plastic from touching metal. Set the oven rack to the lowest height and let the oven preheat completely.
Once preheated, place the headlights inside the oven, ensuring they do not touch the rack or the sides. If using a towel, make sure the side with the channel sealant is facing up. Set a timer for 6 to 20 minutes, depending on the chosen method and your oven's temperature.
Reassembling the Headlights:
After the set time, carefully remove the headlights from the oven using oven gloves or mitts. The headlights and sealant will be extremely hot. Start prying the headlights open with a flat-headed screwdriver, gently separating the seam. Work quickly, as the sealant will start to cool down and harden, making it tougher to release.
Once you have released all the plastic clips, use your hands to pull the two pieces apart. You can now customize the inner chrome parts as desired. Keep in mind that the rubber butyl sealant can be challenging to remove, so be cautious.
Finally, reseal the headlights. Apply a fresh roll of butyl around the headlight housing seam, pressing it firmly into the channel. Cut off any excess butyl. Place the lens and housing together, lining up the tabs. Use pliers or a screwdriver to pull the pieces together, applying even pressure to create a proper seal. Ensure all plastic clips are in place, holding the lens and housing securely.
Cover the lens with a microfiber cloth and use clamps to finalize the sealing process, allowing the assembly to cool down. Once cool, remove the clamps and check your work, ensuring a solid line of sealant around the entire light.
Your headlights are now modified and ready to be installed back into your vehicle!
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Using a heat gun
Firstly, you need to remove the headlights from your vehicle. This may involve unbolting them or accessing them from the engine bay. You should also remove the bulbs. Place a piece of cardboard under the headlight with the clear plastic facing down.
Then, use the heat gun to heat the tabs that hold the flat clips from the clear plastic lens to the black housing. Set the heat gun to high and heat the lower inside corner to the top inside corner. Once the tabs are heated, bend them up.
Next, heat the sealant around the edges of the headlight housing. Keep the heat gun moving slowly to avoid overheating any one area. Once the sealant has softened, carefully remove the headlight assembly and use a flathead screwdriver or plastic prying tool to gently pry apart the lens from the housing. Be cautious not to damage the housing or lens.
Finally, clean the inside of the housing with a clean cloth and a mild detergent solution. Remove any dirt, debris, or condensation that may have accumulated.
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Cutting the headlight open
First, remove the headlight from the vehicle. Depending on the car model, you may need to remove the bumper as well. It is recommended to place the headlight on a stable surface and ensure that you are wearing appropriate protective gear, such as gloves and eye protection.
Next, choose the right tool for cutting. You can use a Dremel, a rotary cutting tool, or an oscillating tool. A fine Dremel disc can be useful for cutting the glued/fused section between the lens and the backing. Alternatively, a tool like the Dremel 3000 or 4300 paired with the EZ476 Thin Cut Wheel can provide precise plastic cutting. When using these tools, always cut slowly and carefully to avoid damaging the lens or housing.
Now, begin the cutting process. Cut along the seam where the lens meets the housing. Work slowly and carefully, ensuring that you are only cutting through the sealant and not damaging any other components. Cut just outside the seam line to create a clean cut, making it easier for resealing if needed.
Once you have cut all the way around the headlight, carefully separate the lens from the housing. Gently pry and separate the two parts, being cautious not to crack the lens. After the lens is removed, you can continue to disassemble the headlight bezel and access the interior for customization or maintenance.
Finally, when you have finished your modifications, it is important to reseal the headlight properly. Clean the inside of the housing using a mild detergent solution to remove any dirt or residue. Dry the area thoroughly before applying a new sealant. You can use a plastic welder, hot knife, or soldering iron to create a strong bond. Apply a rubberized sealant around the seam to ensure watertight protection. Allow the sealant to cool and cure completely before reinstalling the headlight back into the vehicle.
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Removing the headlight from the vehicle
To remove the headlight from your vehicle, follow these steps:
Firstly, turn off your car and remove the keys from the ignition. This is important for safety, to avoid touching any live wires. Then, open the hood of your car to access the headlight assembly. You can do this by locating the lever or button inside your vehicle, usually on the driver's side, and either pulling the lever or pushing the button. Once the hood is open, you may need to remove the bumper cover if it obstructs the headlight.
Next, locate the bolts on the headlight assembly and remove them using a wrench or socket and ratchet. Ensure you remove all retaining hardware before attempting to remove the assembly. After removing the bolts, gently slide out the entire assembly. You may need to apply significant pressure, and it is recommended to use a plastic trim remover tool or a non-marring prying tool to prevent damage to the paint.
Now, disconnect the electrical connectors from the headlamp and parking or turn signal light sockets. There may be a single connector, or you may need to remove the bulb sockets first. Be careful when handling the bulbs, as most will have locking tabs that need to be closed securely. If you accidentally damage the locking tabs, you will need to replace the entire headlight housing.
Finally, carefully slide out the headlight assembly. Reinstalling a new headlight assembly, or performing modifications, will involve working in reverse order. Ensure that you test your new or modified headlights to make sure they are working properly.
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Using a screwdriver
Opening a sealed plastic headlight with a screwdriver is a delicate process that requires caution to avoid damaging the housing or lens. Here is a step-by-step guide:
Prepare the Headlight:
First, remove the headlight from the vehicle. This may involve removing the bumper by unscrewing any screws or clips at the top, bottom, and sides. Disconnect the headlight harness. Place the headlight on a towel or soft surface to prevent scratching the lens.
Soften the Sealant:
To soften the adhesive sealant, you can use a heat gun or an oven. If using a heat gun, ensure the seal is heated evenly by constantly moving the gun. If using an oven, preheat it to between 200-250°F (95-120°C) and place the headlight on a layer of aluminum foil or a rubber baking mat to prevent melting or warping. Heat the headlight for around 12-20 minutes.
Pry Open the Headlight:
Using a flat-head screwdriver, carefully insert the tip into the bottom corner of the headlight, in the seam between the lens and the backing. Gently push the screwdriver into the seam, tilting the handle down towards the backing to lift the lens out of the adhesive. Work the screwdriver around the perimeter of the backing to gradually separate the lens from the housing. Be cautious not to apply too much force, as this could crack the lens.
Clean and Prepare for Resealing:
Once the lens is removed, use the screwdriver to scrape away any remaining old sealant from the backing. Clean the inside of the housing with a mild detergent solution to remove any dirt, debris, or condensation.
Reseal and Reinstall:
Choose a high-quality butyl rubber sealant designed for sealing headlights. Softening the sealant by placing it in hot water or using a heat gun on low heat. Apply the softened sealant evenly around the perimeter of the headlight housing. Reinstall the lens, ensuring proper alignment. Place the headlight back into the oven or use a heat gun to soften the sealant, allowing it to cure. Finally, reinstall the headlight assembly into the vehicle, tightening any screws or bolts to secure it in place.
Remember to work carefully and follow the instructions specific to your vehicle for the best results.
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Frequently asked questions
You will need a screwdriver, a heat gun or an oven, gloves, and a plastic pry tool.
First, remove the headlight from the vehicle. Place the headlight in an oven set to 200-250°F (95-120°C) for 10-20 minutes. If using a heat gun, heat the seam section-by-section, moving slowly to avoid overheating. Once the sealant has softened, use a screwdriver or plastic pry tool to gently pry apart the lens from the housing.
You can use butyl, permaseal, or polyurethane sealant. Butyl sealant is the most frequently used in DIY applications and is ideal for long-term projects. Silicone sealant is better suited for smooth surfaces and provides an excellent seal against water. Polyurethane sealant is intended for commercial use but can be used for plastic headlights.
