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:

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.

Well, Thars yer prawblem!

Chipping off the "sealant"

Much better

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

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

And now put humpty dumpty back together again.

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

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

 

[Ranger#1]

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

 

[Jay FX4]

Nice write up and pics!

 

[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.