DIY: Headlight Mod

[n2titan]

Credit definitely goes to titanse05 and RyBo for their original posts.

Methods

Oven (easier)
Heat gun (harder)



Materials


Gloves
Flat head screwdrivers
Duplicolor primer
Duplicolor black paint or color matched paint
Duplicolor clear coat
150 grit Sandpaper and a sanding block
(2) Permatex Ultra black gasket maker tubes
T10 Torx bits or small screwdriver or eyeglass repair kit can be used
Cookie sheet
Towel
Masking tape



Prepping the headlight housing


Remove all (3) bulbs and wiring from the housing.

Remove the bumper filler. (body color strip under the headlight)

Wipe down the housing from dirt and oils.



Splitting the headlight housing


Preheat oven to 275 degrees.

Towel - Wet the towel, fold and place on cookie sheet.

Place headlight (lens face down) on the wet towel.

Put in oven for 7-10 minutes.
Note: The only thing that should touch the housing is the wet towel.

After 10 minutes, remove the headlight and start splitting.

Note: For me, this is the best corner to start prying. Use a screwdriver to open up this corner. Push the screwdriver in, push it down, then lift up the lens. After, grab the black backing and the corner of the lens and start yanking them apart. There are nine tabs around the headlight that need to be unlatched by a screwdriver.


Remove chrome housing from the lens. Use a T10 Torx bit, small screwdriver or eyeglass repair kit to remove the (4) screws.

Remove the amber reflector from the chrome housing.
Note: This part can be difficult. The chrome area around the amber reflector can break easily. Be patient.

Remove all the original black gasket. You can reheat to soften the gasket or use a heat gun or hair dryer.



Prepping and painting


Masking tape - Mask areas you want to leave chrome.
Note: Some mask around the turn signal section. Some paint everything. If everything is painted, the halogen parking/turn signal won’t be as visible.

Sandpaper - Use a 150 grit sandpaper and sand down all the chrome and wipe down with lint free cloth.
Note:This process will take time.

Primer - Spray at least two coats and wait 10 minutes between coats, then let dry.

Color - Spray the color of choice, then let dry.

Clear coat - Spray the clear coat, then let dry. Remove masking tape.

Amber reflector - Spray with the color of choice or tint spray, then let dry.

Allow all painted surfaces to dry for 24hrs.



Sealing the headlight housing


Make sure everything is clean, oil free and dust free.

Amber reflector - Reattach to painted housing.

Painted housing - Reattach to lens.

Gasket maker - Apply to the headlight backing in the groove where the lens will sit.

Lens - Reattach to headlight backing. Make sure the 9 tabs connect and apply pressure to properly seal.

Bungee cords - Wrap around headlight housing maintain pressure while the gasket dries.
If you don’t have bungee cords, use what you can to maintain pressure ( try a belt, or use the masking tape. )

Allow the gasket maker to dry for 24hrs.


Happy modding!




If you don't have the time or material to do this mod, PM SiMpLyMoDiFiEd.
He's done many Headlight Mods for Titan Owners.