How To pull headlights apart for LED mod

So I have received many requests for instructions on how I’ve built my headlights and taillights. Just know in advance, if you perform my steps, and destroy your lights, I will not be held responsible for it. Have patience, and continually watch the heating process to ensure you don’t mess your lights up.

Anyway, I use my oven to melt the sealant that holds the two halves of the light housings together. If you are going use this method, please note that ovens have variations across brands, types, elevation, etc… so this is why I say keep monitoring your lights so you don’t melt them. Turn your oven on to bake, and set it for 250 degrees, let it warm up and reach this temperature so there’s no change in heat after you place your lights in the oven. Also, pull out all the racks inside except one and put it at the lowest level so your lights sit closer to the heating element. In addition to this, place a metal baking sheet on the rack, DO NOT put your lights on the rack itself. So, without further bold type, follow these steps (at own risk):

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• First off, remove the round access covers enclosing the bulbs, remove the bulbs (without touching the glass, or if you do, wipe off any finger prints and smudges), and remove the metal clips that hold the two halves together. There should be three on the top, and three on the bottom. Also be sure to remove the bulb for the turn signal if you didn’t pull it out during removal of the headlight assembly. (This headlight is a spare I had and already has most of these removed, but it’s self-explanatory)

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• After removing all those parts, you’re ready to bake your lights. Place the housing in the oven (on your baking sheet). Ensure your light assembly is situated in the oven so it’s not touching the sides or top of your oven, they’ll melt, and keep it in for eight minutes. This is how long I keep mine in for the initial heating period. After the eight minutes, pull your light assembly out, and be smart, don’t burn yourself…..

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• After you remove your light, gently pry the housing halves apart. Use a knife or flat heat screw driver if you need something to help the separation along, also to cut through the sealant. If you’re having problems pulling them apart, stick the housing back in the oven for a couple more minutes, however long you feel comfortable with. I tend to need to do this every time, which is better than leaving the lights in longer at one time. Take precautions against melting your lights.

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• After you’ve pulled the halves apart, remove the two tiny screws holding the black inner light trim to the headlight lens. This is the part I’ve mounted all my LEDs to. I won’t go into that part, as everyone will most likely want different set-ups.

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Hopefully this is what everyone was wanting me to post, if not, I'll do another.


• This is my current set-up I’m working on:

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[spyderdrifter]

So it has been brought to my attention that for those of you out in the community who are new to taking your lights apart, that you should use a different way of heating your lights, so that its safer for them without the risk of melting them.

You can do everything the way I've written, but you can turn off your oven after preheating it to avoid constant heat radiating to the back half of the light housings as that plastic has a lower heat tolerance and will melt before the lens. All credit for this goes to azdave. The most important thing for this though, is to have patience and take your time.