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.

Couldn't resist doing a bit more detailing I'm afraid.

WOW!!!! Nice work, they are better than new :]

 

just for info, It is possible to remove the glass from the headlight without taking the full housing out! I know this doesn't apply to your full rebuild, but for peeps just wanting to clean up inside the light unit, its possible

WOW!!!! Nice work, they are better than new :]

 

just for info, It is possible to remove the glass from the headlight without taking the full housing out! I know this doesn't apply to your full rebuild, but for peeps just wanting to clean up inside the light unit, its possible

 

Thanks mate.

 

As for removing the lens in situ? My initial thought would be that it would not be possible. The reason

I say this is that the surrounding brackets that help to hold the seal in place would be in the way.

To be honest, I never took much notice when I removed my lights, but I did take plenty of pictures.

When I get a chance, I will look back through them and check for you.

Looking better than new!

 

WOW!!!! Nice work, they are better than new :]

 

just for info, It is possible to remove the glass from the headlight without taking the full housing out! I know this doesn't apply to your full rebuild, but for peeps just wanting to clean up inside the light unit, its possible

 

Sorry to jump on your thread, but how can you just remove the glass for cleaning?

I did write a short thread a few years ago on how to do it, but as I can remember, remove the Centre panel, unclip the metal clips from around the housing and heat the glass around the edges with a heat gun, obviously taking care not to melt the wings and bumper ( cover them up) and slowly work your way around with a large screwdriver/ scraper and pull the lens off. There may be a few other little bits I've forgotten but it's fairly easy, I've done it to both my zeds. When I'm back on my pc ( not my phone) I will post a few pics ;)

I did write a short thread a few years ago on how to do it, but as I can remember, remove the Centre panel, unclip the metal clips from around the housing and heat the glass around the edges with a heat gun, obviously taking care not to melt the wings and bumper ( cover them up) and slowly work your way around with a large screwdriver/ scraper and pull the lens off. There may be a few other little bits I've forgotten but it's fairly easy, I've done it to both my zeds. When I'm back on my pc ( not my phone) I will post a few pics ;)

 

Sorry DaZvert, I just re read your post. I thought you asked if I thought it was possible to remove the lens. Sorry to appear to contradict you mate.

I must learn to read things a bit more carefully. lol

WOW!!!! Nice work, they are better than new :]

 

DITTO!!!! look fantastic!!!

That's brilliant mate

Thanks guys.

 

I thought I would final fit one of the adjusters along with wavy washer and new star spring clip washer.

Before assembly, I did pack the gears with new grease also, along with a liberal coating on the O ring.

I have to say, it does feel a lot smoother. Well worth the effort I think.

 

One thing I was a bit unsure of, was manipulating the sealant evenly back into the groove, but with some advice from Medallion Man it went fairly well.

Just need to be careful now when final fitting, I will have to keep things warm as I screw the 2 halves together.

Firstly, apologies if I am pushing this thread too much. The last thing I want to do go overboard with it.

 

I fitted the side panel today complete with sealant. One thing I would say is, if anyone is contemplating doing the same. Please make sure you press the cover all the way home around all edges before tightening the screws. This way you will avoid pulling down the local area around the screw itself and fracturing the mounting points of the cover.

 

I would add also, It was well worth re working the sealant level before fitting, It really did help with an even overspill once fitted.

Managed to finish off the second side today.

Both went very well. Mind you, I did manage to use a little more sealant on my second attempt.

Well I thought I have come this far, so might as well go the whole hog and strip off the original sealant.

Not sure weather to re use the existing or go for new though.

Well, I thought I would look into the possibility of getting the reflectors re silvered. (Vacuum Metallised to be more precise)

After a short Google, I managed to find a company close by that will be able to help.

So, having spoken to the guy there, I decided to strip back most of the reflector and let him have a look at them tomorrow. Once done, they should look as good as new.

(if not better)

Great thread of zedication. Love it..

Great thread of zedication. Love it..

 

Cheers Znut :thumbup1:

Dropped the reflectors off today, should be ready for Monday.

Then the re build can really begin.

In the mean time, I stripped the rubber sealant from the second housing. Now I have a matching pair!

God! I hope you guys are not getting fed up. lol

Dropped the reflectors off today, should be ready for Monday.

Then the re build can really begin.

In the mean time, I stripped the rubber sealant from the second housing. Now I have a matching pair!

God! I hope you guys are not getting fed up. lol

 

not at all mate,keep the updates coming.

Finally, after hours of cleaning etc' I can now start rebuilding.

So I started final fitting the rest of the adjusters, packed with grease for good measure.

Happy days!

Not a chance, brilliant thread, keep it up.

Good job mate!

Are you metallising the inserts too?

Edited January 11, 201411 yr by mantav8

You've done a serious refurb on them mate. Looking better than new :bow:. And don't be daft about boring us! This is exactly the sort of thing we want to see :)

Good job mate!

Are you metallising the inserts too?

 

Mmmmmm, Thats a good thought Mantav8.

I was looking at staying original, but will seriously think about your idea.

Nice one.

You've done a serious refurb on them mate. Looking better than new :bow:. And don't be daft about boring us! This is exactly the sort of thing we want to see :)

 

Cheers Streams.:thumbup1:

Glad that my efforts are of interest

 

Managed to get both sets of adjusters fitted today, and even if I say so myself, they do feel very smooth.

Well chuffed.

 

Can't wait to pick up the reflectors next week.

In the mean time, I will be cleaning up the glass.

Also, I will be stripping the ancillary metal work back to bare metal ready for new paint.

I was thinking about using the original seal that surrounds the headlights, but having gone to this much trouble, I would like to fit new.

Are they still available does anyone know?

Can you do mine next :lol:

Not much in the way of progress today I'm afraid.

Still, every little bit helps I guess.