Gen 2 Headlamp repair

[MagnaV30]

After a while I have noticed that a few Gen 2's have developed a condensation issue inside the headlamps due to a leaking seal between the refractor lens and the reflector housing.

So, lets fix that shall we?

The problem:

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0087.jpg

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0088.jpg

Okay, so we must separate the Refractor from the reflector.
Some may have done this by baking in the oven, however, on the gen 2 the entire headlamp assembly is constructed of plastic for the reflector and polycarbonate for the refractor. Not feeling the need to end up with a bubbled shapeless mass, I simply used and infinite (or infintesmal) amount of patience, and pried the components apart.

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0089.jpg

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0090.jpg

Well, Thars yer prawblem!

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0091.jpg

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0092.jpg

Chipping off the "sealant"

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0094.jpg

Much better

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0095.jpg

Might as well polish the lens while you have it off.

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0096.jpg

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0097.jpg

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0099.jpg

Now, fill the nice convenient channel with sealant, I used a polyurethane produced by DAP available at most hardware stores.

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0101.jpg

And now put humpty dumpty back together again.

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0102.jpg

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0119.jpg

Now use some tape to exert some clamping force for the curing of the sealant.

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0125.jpg

I rate this project with a difficulty of "Very little blood loss"

http://img.photobucket.com/albums/v719/MagnaV30/Working%20on%20Insanity/DSCF0098.jpg

[Ranger#1]

good ima gonna be doing thiss tomarrow what did u use to dry the reflector

[Jay FX4]

Nice write up and pics! :icon_thumby:

[MagnaV30]

Thanks! I plan on doing quite a few more write ups and taking a pile of photos along the way.

Ranger #1
I simply used a microfibre cloth to clean both reflector and refractor, and I polished the refractor with (dont laugh, it worked really well) Mothers aluminum polish.

Just be really carefull when separating the components... I left the assembly mounted to the vehicle, which helped considerably (and kept me from having to seriously re-aim), but it still took me almost 30 min to slowly pry everything apart. I used a combination of a knife, and two thin screwdrivers as prying tools.

My next lighting mod is likely to be gutting the clearance and turn signal lamps, and filling them with LED's

I will be posting them in the write up thread, and in relevant sections as I complete each mod.