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post #1 of 19 (permalink) Old 06-24-2012, 06:36 PM Thread Starter
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oppening headlights questions

I'm working up to opening my headlights to do a retrofit of the halogen projectors, since this is my first time doing this I have a few questions.

1. When I re-seal the headlights what kind of glue should I use to re-seal with? I talked to theretrofitsource and they said i could add some glue to the factory stuff and it would be fine, but which kind should I buy?

2. When putting the headlights in the oven I have seen a video where the person put some kind of protective paper over the clear part of the headlight body, what is that stuff and where can I buy it? I would like to do everything possible to prevent damage to that part.


-Shaun
[size=6pt]Mods: 17x7.5 rims w/ Conti DWS tires | 4 75W kicker speakers | Memphis 300W amp | full size spare | BC Condenser kit w/ extra grounds | CS SRI w/ box | timing advance | upgraded horn | CS LED kit | Axela badge | alu pedals | Momo shift knob | Alu fuel door | footwell LEDs | VTCS delete | TB coolant bypass | L fog light vent | bi-xenon HB/LB | HID fogs | SB LED turn sigs | LED DRLs | LED reverse lights | painted foglight trim | LED tail lights | LED reflectors[/size]
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post #2 of 19 (permalink) Old 06-24-2012, 11:38 PM
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Re: oppening headlights questions

TRS's butyl rubber gasket(glue) is fine. Usually for first time open, gasket is still in better condition, but can't hurt making sure good seal.

2010+ model head lamp is made by Koito and they use rather tough butyl rubber mix. Make sure warm up enough to soften gasket when open/close.

You can just use cardboard or something, it's just to block direct heat radiation onto lens. Lens material Poly-carbonate temp rate is around 150C to 180C (melting temp is around 250C) Housing material Polypropylene temp rate is around 130C to 165C in general

TRS recommended 265F for 7 minutes seems bit high temp to warm up, I usually do around 200F to 220F for 10min to 15min

Make sure any part of headlamp not to be placed too close to heating element.

BTW, you are going to retrofit halogen projector? in place of original halogen projector??
2010+ Mazda 3 halogen projector is pretty good one already for halogen projector.





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post #3 of 19 (permalink) Old 06-25-2012, 12:44 AM Thread Starter
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Re: oppening headlights questions

I thought about trying to use the halogen projectors but decided instead to go with a bi-xenon projector that way I get the bi-xenon functionality and "flash to pass" without having to keep the OEM high beams or use some kind of 6000K halogen bulb (which would suck). The plan is to have the bi-xenon in the projector be my high and low beam and put an LED bulb in the high beam parabolic housing and have it come on with either the high or low beam lights (I can do either easily with the TRS harness).

It sound like it might actually be safer to heat up the headlight a bit in the oven then finish with a heat gun, I have a decent heat gun. What method do you recommend for the gen2 headlights (heat gun or oven)?

-Shaun
[size=6pt]Mods: 17x7.5 rims w/ Conti DWS tires | 4 75W kicker speakers | Memphis 300W amp | full size spare | BC Condenser kit w/ extra grounds | CS SRI w/ box | timing advance | upgraded horn | CS LED kit | Axela badge | alu pedals | Momo shift knob | Alu fuel door | footwell LEDs | VTCS delete | TB coolant bypass | L fog light vent | bi-xenon HB/LB | HID fogs | SB LED turn sigs | LED DRLs | LED reverse lights | painted foglight trim | LED tail lights | LED reflectors[/size]
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post #4 of 19 (permalink) Old 06-25-2012, 12:47 AM
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Re: oppening headlights questions

All heat gun all the time. To me the oven takes too long.



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post #5 of 19 (permalink) Old 06-25-2012, 12:50 AM Thread Starter
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Re: oppening headlights questions

The heat gun seems less risky to me since the heat is directed only where you want it.

-Shaun
[size=6pt]Mods: 17x7.5 rims w/ Conti DWS tires | 4 75W kicker speakers | Memphis 300W amp | full size spare | BC Condenser kit w/ extra grounds | CS SRI w/ box | timing advance | upgraded horn | CS LED kit | Axela badge | alu pedals | Momo shift knob | Alu fuel door | footwell LEDs | VTCS delete | TB coolant bypass | L fog light vent | bi-xenon HB/LB | HID fogs | SB LED turn sigs | LED DRLs | LED reverse lights | painted foglight trim | LED tail lights | LED reflectors[/size]
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post #6 of 19 (permalink) Old 06-25-2012, 01:26 AM
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Re: oppening headlights questions

Heat gun should be supplemental option.
You want to warm up entire butyl gasket evenly when opening or closing. Heat gun heat will be too directional in headlight open, close case.
Housing is fine in 200F range oven as all materials constant temp rate is at least 250F.

Those headlight seal butyl rubber is rather higher temp stable type, local heat up with heat gun leave not warmed enough gasket area.

Heat up evenly with oven, open/close promptly and when need extra heat touch up, use heat gun.

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post #7 of 19 (permalink) Old 06-25-2012, 01:51 AM
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Re: oppening headlights questions

When use oven, place headlight on cardboard, make sure any of headlight housing, lens is not touching metal part(rack, wall, heating element) of oven.
Place another cardboard or paper over housing so upper heating element won't directly radiating heat onto headlamp.

If you go for heat gun, be careful not to heat up too locally. Housing temp rate is little lower than lens.
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post #8 of 19 (permalink) Old 06-25-2012, 07:38 AM
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oppening headlights questions

I've opened my headlights twice and I have to say along with minitrucker; heat gun is the way to go.

I first tried it in the oven, and there was 3 of us trying to pull it apart.
Luckily I didnt burn the plastic lense; others haven't been so fortunate.

Heat gun the 2nd time around took 8 or so minutes per lens (not 20). So literally with heat gun it was FAR safer, and I had both open before one would've been open if I used an oven for 15 minutes

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post #9 of 19 (permalink) Old 06-25-2012, 08:32 AM
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oppening headlights questions

+1 heat gun. I did the 2010 with it


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post #10 of 19 (permalink) Old 06-25-2012, 10:24 PM
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Re: oppening headlights questions

+1 for a flamethrower. Takes like seconds.

All serious kidding aside, the heat gun is where it's at. Pics pics PICS!!


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