Well I must be missing a trick here.

How the hell are you supposed to remove the passenger headlight without taking the whole car apart??

Driving me mad!!

Any suggestions would be appreciated.

As it stands at the moment, I can't see anyway around dropping the recirculation valve just to get access to the last bolt.

Is there an easier way?

Talk about frustrating or what.

Thanks guys!

I have decided to tell myself.. If at first you don't succeed, try try again.

After all, if I have to strip and clean the thing again then so be it.

Oh well.

Yet again some attention to detail that you always seem to bring to the table.....

Looking superb.... I know you will end up taking them apart and redoing them till you are 100%...... lol

You are a perfectionist...... I know what I will be doing over the next month or so now...... lol

Nice one....

Cheers Russ.

 

Decided to take a bit more of a measured approach on the second headlight based on the results of my first attempt.

So I am going to make up individual strips of sealant varying in size depending on the sealed edges.

I have seen from my initial attempt that there was to much sealant along the sides (making it difficult to disperse) and not enough sealant in the corners.

So far I have laid sealant down the 2 edges just to the top of the channel.

 

As I was re softening the original rubber so as to tease it into shape, I decided to experiment with temperatures so that when it came to re locating the lens for sealing, not only was the rubber at it's softest, but the housing was equally pliable so as to be flexible and not softened or deformed.

 

My plan is to lay the rubber in correct thickness' into the housing and then warm the headlight and the lens at the same time and then bring them together.

Hopefully the sides will seal without overflowing and the top, bottom and corners will seal with enough excess rubber to seal and then spread out.

Also, meant to add. I have, on good advice, replaced the original moisture absorbent tablets with some sachets of Silica Gel.

Decided on a permanent fixing as opposed to placing them in loose.

nice cocain stash there mate:tongue_smilie:

nice cocain stash there mate:tongue_smilie:

 

Damn! Rumbled.:lol:

 

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Finished laying my second attempt of sealant. I have tried to apply what I have learnt from my previous efforts.

IE I have build up the corners, etc'

Well can not believe it!! failed a second time.

That said, this attempt was better due to the better placing of the sealant but still I have gaps!!

Looks like they will both be coming apart for yet another go.

I will get there in the end. I hope.

Well, decided to split the headlights yet again in the hope that I can achieve an all round even seal.

Looking at certain areas, I have since noticed that the sealant was not laid down correct on my previous attempts.

I have since discovered that the overhang of the black insert varies, especially near the bottom corners.

So rather than pushing the sealant up against the vertical wall of the casing, I will stay away a few millimetres.

Not only will this contact the glass better, it may even allow more room for displacement.

I can but try.

Decided to take a bit more of a practical approach this time as I know a little bit more about how the glass sits in the housing.

Apart from being a bit more precise with regards to not only the amount of rubber I put down, (I think on my previous attempt there was too much) but also tried to place the sealant exactly in line with the sealing lip of the glass.

I did this by placing the glass on several times and adjusting the position and amount as I went.

I still have some smoothing and adjustment to do but I am almost there.

I was going to mention using plasticine to get your thickness right then easily removed but it looks like you have cracked it mate (excuse the pun)..well done:thumbup1:

I was going to mention using plasticine to get your thickness right then easily removed but it looks like you have cracked it mate (excuse the pun)..well done:thumbup1:

 

Nice idea znut.

May try that when I re separate the first one I did.

As you say, it certainly would save a lot of messy cleaning.

 

Before I try yet again to seal the glass on this one, I shaped the sealant just a little more so as to get closer to the edges as opposed to just laying a round bead.

I just hope that I have got the balance right between too much rubber and not being able to close the thing, and not too little so as to not give a good all round seal.

I am beginning to regret bl**dy starting this. lol

So, after what must be my fourth attempt, things are starting to look promising.

I have managed to get a good seal to the top edge, top corners, sides and bottom corners.

My only disappointment is the bottom leading edge. It looks like I was a little shy with the sealant.

 

I thought that if it was going to seal, I might as well sit it in the sink full of water.

At least although it does not look as good as the surrounding seal, if it kept the water out then it will do the job.

So it is now sitting in 4 inches of water, fingers crossed.

Well, after half an hour or so submerged in warm water there appears to be no ingress of water.

Dried everything off and tried to see if there was any sign of a leak but appears not.

Looks like this one has passed.

nice job... they are going to be the most perfect Zed lights on the planet.. :)

nice job... they are going to be the most perfect Zed lights on the planet.. :)

 

cheers mate.

So, with one headlight sealed, (eventually) and put to one side, I have laid the rubber down for the second one.

Taking on board my previous attempt, I have applied a greater thickness to both bottom corners and along the front edge.

Hopefully not too much. doh. So tomorrow will be when I set the lens, seems like I have been on these for bl==dy ages.

Oh yeah, I have. lol

So, with one headlight sealed, (eventually) and put to one side, I have laid the rubber down for the second one.

Taking on board my previous attempt, I have applied a greater thickness to both bottom corners and along the front edge.

Hopefully not too much. doh. So tomorrow will be when I set the lens, seems like I have been on these for bl==dy ages.

Oh yeah, I have. lol

Well, after all my trials and tribulations, this attempt went really well.

There was slightly more sealant than needed, which after what seemed like hours wrestling the thing around the kitchen work top, finally settled down enough for me to get the clips on.

I am really pleased with the even coverage between the glass and the housing, I feel a lot happier that this will be a good seal.

Believe it or not, I am actually contemplating trying to get the first one as good as this one. (Somebody stop me!) lol

At last, finally started to put things back together.

I thought I would put the bulbs and connections back first as I hope to try them out later tonight.

After that I will be tackling the framework that retains the headlight and also the surrounding seals.

I think I will get them powder coated black as they are a bit tatty.

Ime still finding it hard to absorb your attention to detail mate...The best refurbed front lights ive ever come across:bow:

Ime still finding it hard to absorb your attention to detail mate...The best refurbed front lights ive ever come across:bow:

 

Thanks again mate, I really do appreciate your comments.

 

Managed to plug them in temporarily just out of excitement and impatience, at first glance they do look super bright compared to before.

My only concern was when I viewed the pictures, there seems to be a very fine speckled effect on the outside of the lens.

This was only visible once illuminated. I am not sure if it is mini stone chips or a sort of tarnish.

 

 

Can anyone advise a polish or cutting compound that may improve the finish?

Not much in the way of progress, just paint stripper and elbow grease so as to get the brackets etc' back to bare metal.

All in all they have stood the test of time quite well, not too much rust at all really.

My plan is to remove most of the rust and then neutralise the stubborn stuff.

Well not much in the way of progress of late, but did manage to get the use of a shot blaster so as to ready the headlamp brackets for paint.

If all goes well, I will have them ready for fitting tomorrow.

My only concern was when I viewed the pictures, there seems to be a very fine speckled effect on the outside of the lens.

This was only visible once illuminated. I am not sure if it is mini stone chips or a sort of tarnish.

 

You've got remember these are 20 year old lenses and if you've cleaned them thoroughly and held them up to the light then there's very little you can do about it, as with everything some used lenses are better than others.

 

Fyi, when i have cleaned them i just use hot soapy water with a brillo and usually do it at the same time as i bring the rubbers back to life.

 

What colour you doing the metal rubber holders......got to be gloss black as it ?

You've got remember these are 20 year old lenses and if you've cleaned them thoroughly and held them up to the light then there's very little you can do about it, as with everything some used lenses are better than others.

 

Fyi, when i have cleaned them i just use hot soapy water with a brillo and usually do it at the same time as i bring the rubbers back to life.

 

What colour you doing the metal rubber holders......got to be gloss black as it ?

 

I take your point Phutumsch, all in all I guess that they are not too bad considering the age as you say.

I will try the Brillo and hot water tip though, as I have still yet to clean the rubber seals so will do them at the same time.

 

As for the metal work? Gloss black as you said.

Just going for the original look.

Just hope that I can get a reasonable finish.