I've just refurbed my headlights, and i'm now beginning to notice moisture forming on the inside of the headlight glass while the lights are on. this disappears within a few hours after turning headlights off, I put extra silica gel bags inside the headlights along with the original silica tablets when I reassembled the lights. i'm thinking the worse and it could be the seal around the glass maybe? although I did make sure this was heated and a good amount of seal oozed to the glass edge. i'm running HID's but the problem is also there with standard h3c lamps in.

Not sealed properly mate.

it may just be that there is some moisture in there, you could try using a hair dryer to blow hot air in and clear/blow the moisture out (not too hot)... at least that way you would know if its leaking (i.e. if it comes back).

As above.

I recently refurbished mine, and for a couple of weeks after I did get condensation.

All appears fine now.

I've had them back off this afternoon and checked them it seems the bottom edge and corner is slightly misshaped on one where the headlights had been dismantled before I bought them so after I had clipped/clamped them back together because I used butyl rubber sealer rather than the grey original it says slightly flexible so the gap reopened. just had the first one apart and applied some extra sealant across the bottom edge & corner and reheated it, it's now clamped up correctly and i'm going to run some silicone around the edge of the glass to make extra sure it's sealed.

 

i'll look at the 2nd one tomorrow

You will have removed the silica tablets that were in there from new that are supposed to soak up any condensation, you can add a silica gel bag or two to help prevent it in the future :thumbup1:

I already had the 3 silica tablets in plus 3 extra bags of silica as well