Navaros911

Reflector and projectors back in place - reverse of removal. Just four screws for the main projector and two screws for the reflector.




Now you need to slide the silver painted piece into the housing and test fit the lens over it.

All of this needs to be held in place with some adhesive. I read butyl tape was the way to go... but it doesn't hold much in place, it's more like a seal.

So first some specific epoxy. I used PC-autobond because it has a little give in it. I used it to hold the lens in place. Then used the butyl tape to ensure it was sealed.



Doesn't look great, but does the job.

The butyl tape I used -> $5



And the result is:

Navaros911

Tools used:

Box knife
Torx set
Screw driver
Pliers to squeeze the electrical connectors

Epoxy to glue some plastic parts together when you break or crack the lip.

Lessons learned:

1/ The epoxy at some points does not hold enough... the butyl tape seals, but doesn't work as an adhesive.
2/ Don't touch the light bulbs with your hands -> just remove them from the start and don't drop them (obvious)
3/ The corner lights ALWAYS provide a little light when the main beams are on.
4/ You need to have a parking light (or whatever those little light bulbs are called) functioning in the unit, without it, you get alarms. Perhaps a resistor would work as well, but I just glued (epoxy) the actual bulb in the rear housing out of touch of any wires.
5/ Any type of cleaning of the inside lens that gets you to touch the chromed part rubs off the chrome. To clean, just put some distilled water and maybe methilated spirits in the housing and slosh it around a bit, then pour it out.


Next:

Since the lenses have started to separate from the body, I'm going to re-seal with silicone. The butyl tape may work in low temp climates, but in high temp climates, it lets go. Silicone can take much higher temps and I hope it keeps it all sealed up.

Install some DRL solution that can function as the parking lights.
Legally I can remove that light bulb here... but to be sure, check your local regulations.

Cole

Sweet! Good work!!


Would have loved to see them in body color!

deilenberger

Amazing job and great writeup - especially about what to avoid. I was wondering about cleaning the optics - the projector lens in particular.. can this lens be removed from the back (I assume after taking all the HID mounting stuff off..)?

And can it be removed without touching the chrome (the lesson to be learned from your writeup.)

Jochy

Aligned pointing downwards, right?
You mean the rear duck neck ventilation tubes right?

Navaros911

Yes. Probably one of the easier things to do. All from the back.

Some torx drivers and two hands is all you need.

Unplug the two electrical connectors (you can't reverse them, so no need to mark). Undo the four screws in the corners of the projector. Slowly pull it out.

Not much risk of touching chrome, unless you're very careless.

I suggest you remove the bulb.

This will only work on the main projector.

Navaros911

Yes, you got it.

Navaros911

Cole,

I thought about it, but there is so much satin silver trim on this car that I wasn't sure how it would look in blue.

My intro thread is taking form, so you'll see what I mean soon enough.

Thanks for the info from your thread... that's what inspired me to even get started on it.

Navaros911

So latest update:

about 10 months into the fix here's what I've learnt

1/ Silicone works to keep the units together, but you need to make sure it is perfectly sealed (one of my units mustn't have been sealed perfectly from the start, but it did after a few weeks)
2/ the chroming process on the headlight parts does not hold up, it starts to yellow and tarnish (I think going to silver paint is a better idea, and I will combine this with body color surrounds next time)
3/ there is always a DIY on this car that I can stay busy with