Separating the lens from the headlight?

[FerociousNINJA]

Anyway of separating the lens from the headlight? I just noticed it's siliconed together.

Thx

[kkim]

why would you want to do that?

[FerociousNINJA]

Originally Posted by kkim

why would you want to do that?

Got these H4/35w I want to Retrofit... Reviewing first. Did not expect silicone. Was expecting something similar to a cars headlight like tar. Have already done this once on my project car.

[kkim]

yep, I was going to suggest putting the headlight in an oven at low temps for a few minutes to soften the adhesive. are you sure that won't work?

if not, your only option would be to carefully slice it open on the seam with a sharp, razor type knife.

[FerociousNINJA]

Was thinking the oven or a heat gun. For the oven option I need to remove as much metal as possible. I think it's has to be set @ 350 F for 7 minutes max. Read that somewhere on another moto forum a while ago.

EDIT:
Found some DIY info regarding the bake temp, etc...
http://www.kawiforums.com/how-tos-fa...fit-636-a.html

[kkim]

Originally Posted by FerociousNINJA

Was thinking the oven or a heat gun. For the oven option I need to remove as much metal as possible. I think it's has to be set @ 350 F for 7 minutes max.

I've heard lower temps than that in the automotive forums. time in the oven is critical too, otherwise you end up with melted/mishapened plastic.

[Ken08Ninja]

Even baking the housing it was a PITA to get the headlight open.
The projectors are too long to fit in the housing without modifications. I had to enlarge the openings and make some new mounting spacers to get the lense cover back on. I would consider buying a used housing to test on.

[FerociousNINJA]

Originally Posted by Ken08Ninja

Even baking the housing it was a PITA to get the headlight open.
The projectors are too long to fit in the housing without modifications. I had to enlarge the openings and make some new mounting spacers to get the lense cover back on. I would consider buying a used housing to test on.

Ken on what did you place the HL when put in the over. I'm assuming the metal grill will melt the HL. Ken can you post some pics of your finished project?

I did pick up a new housing on ebay to test. I also did some measurements last night of the depth. Seems like I need to put the H4 aside and order the 9005/9006 ones due to the shorter length. I'm going to try the oven bake this weekend. I will post results.

[Ken08Ninja]

Originally Posted by FerociousNINJA

Ken on what did you place the HL when put in the over. I'm assuming the metal grill will melt the HL. Ken can you post some pics of your finished project?

I did pick up a new housing on ebay to test. I also did some measurements last night of the depth. Seems like I need to put the H4 aside and order the 9005/9006 ones due to the shorter length. I'm going to try the oven bake this weekend. I will post results.

I followed this guide on KawiForums http://www.kawiforums.com/how-tos-fa...rojectors.html

Except I wired the Halos to the low beams and put a switch on the low beam wire so I can just have the Halos on when parked. This way the stock switch still changes from highbeam to lowbeam.

Will the 9005/9006 ones fit in the hole properly?

[FerociousNINJA]

The 9005/9006 seem shorter length. I would need to adapt them or go with the H4 that I have. I could order the H7 but am concerned with the length. I don't want to dish out $150 and run into issues.

I separated the HL using a heat gun for about 30min. First time is always the longest. Here is a pic. I think my finger tips are burnt.

[kamikaze]

Originally Posted by FerociousNINJA

The 9005/9006 seem shorter length. I would need to adapt them or go with the H4 that I have. I could order the H7 but am concerned with the length. I don't want to dish out $150 and run into issues.

I separated the HL using a heat gun for about 30min. First time is always the longest. Here is a pic. I think my finger tips are burnt.

would the whole reflector come out of the housing? I wonder if that would get you just enough room to go with the other projectors like the one i mentioned in the other thread? it's not like you'll be needing the reflector anymore anyway...

the plastic behind the reflector probably doesn't look as nice, but there's nothing saying you couldn't vacuum form a nice shroud to make it look better

[sherjay]

please try to post a DIY with pics. this is an awesome project. R u planning on using both projectors or just one? you would definitely need to bore a hole to fit the projectors. take your time to get the perfect fit. Good luck and have fun.

[FerociousNINJA]

Originally Posted by kamikaze

would the whole reflector come out of the housing? I wonder if that would get you just enough room to go with the other projectors like the one i mentioned in the other thread? it's not like you'll be needing the reflector anymore anyway...

the plastic behind the reflector probably doesn't look as nice, but there's nothing saying you couldn't vacuum form a nice shroud to make it look better

Yes the reflector will come out of the housing. I want to keep my reflector and will paint it stain black. I will need to use a dremel to make the opening bigger since I decided to pull the 35w H4 Bi-HIDs from my project car.

Originally Posted by sherjay

please try to post a DIY with pics. this is an awesome project. R u planning on using both projectors or just one? you would definitely need to bore a hole to fit the projectors. take your time to get the perfect fit. Good luck and have fun.

I will take pics and do a write up DIY if it works out. Yes will have to bore the hole and your right I will take my time to do it right . I want to have both HL ON at the same time... Much brighter.

[kamikaze]

Originally Posted by FerociousNINJA

Yes the reflector will come out of the housing. I want to keep my reflector and will paint it stain black. I will need to use a dremel to make the opening bigger since I decided to pull the 35w H4 Bi-HIDs from my project car.

how much extra room do you figure you'd get if you pulled the entire reflector?

[FerociousNINJA]

Originally Posted by kamikaze

how much extra room do you figure you'd get if you pulled the entire reflector?

aprox 1/2" more.

[kamikaze]

Originally Posted by FerociousNINJA

aprox 1/2" more.

cool, thanks

[randomwalk101]

Cool project. Post up some pics

[Ken08Ninja]

Dave, I took some photos of my setup for you. I painted both the projectors and stock reflector Black.

[FerociousNINJA]

@Ken08Ninja
Thanks, that looks awesome! Love the halOOs! Thanks for the blue line showing where it sits in the reflector. I'll work on this some more this weekend and take pics.

[Ken08Ninja]

Dave, they are almost touching the lense cover even after sinking them in the reflector. The last photo I posted shows where I have them making contact with the reflector.

Ken

[FerociousNINJA]

Ken, I did a test placing my figure 1" away from the HID... with in a few secs OUCH! that gets damn hot. My concern is sitting them as far back as possible to avoid melting the lens. Not sure how hot the lens gets with the OEM setup ans it seemed that the rear part of the reflector has a metal coating.

Also how much does it stick out from the back? Does it touch anything?

[Ken08Ninja]

I bought a 50W 4300K kit. I've never checked to see how hot my lights get. I've had mine now for about 4000 miles, the lense has not melted or discolored any. If yours are 35W they should be fine.

There is plenty of room behind the headlight. If you made a new mount to replace the stock reflector you could have them farther away from the lense cover.

[FerociousNINJA]

I am so upset! I was working on this mod getting ready to reassemble everything then the cord to one of the HID snagged at the edge of the table and slip out of my hands hitting the floor and cracking the reflector.

Any advise on what type of plastic to see if can weld it?

EDIT 2010-09-23:
The plastic material is Polyphenylene Sulfide (PPS) Plastic.
http://en.wikipedia.org/wiki/Polyphenylene_sulfide