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Painting Headlights, Halo's and Clear SideMarkers
Here's my writeup on How to take apart your headlamps for paint, clear sidemarkers or adding Halos.
- First, there are some tools needed (pictured below).
- You'll need to start by removing your grill and bumper to get to the bolts that hold your lights to the max.
- You need to remove all bulbs and balast (if equiped) and remove any wiring that is easy to get to.
- There are 2 small black screws on the back that sometimes get missed, make sure to get them off, before you disassemble.
- You'll then need to open up your headlights by baking them in the oven at 225 degress to loosen the seal that holds the lens to the body of the housing. If it still wont open up, check to make sure all screws holding it together have been taken out. (Don't touch the hex head bolts. Those are for adjusting the projector lens) Bake again for 15-20mins at a time till it opens.
- Next comes the paint, I recommend krylon fusion gloss black as it doesn't require any sanding or clear coat.
- If installing Halos, it gets alot trickier. Tape them to the mounting area and mark out 2 holes each to run the wires through. Drill the holes the same diameter of the ends of the halos. Run the wires through there and hold the center top in place w/ painters tape.
- Halos cont..- using 2 part clear epoxy, dab enough surrounding the mounting holes to keep halos in place on the bottom, then after the bottom is dried, add a small amount of epoxy to the top center of the ring.
- Halos cont..- mount the halo inverter inside the area where the canadian running lights are w/ 3m double sided tape. Drill a small hole out the back where a bulb would go and add an appropriate sized rubber grommet there to run the red and black wires through.
- Halos cont... - You also need to drill a hole in the side of the running light area to be able to feed the 4 white halo wires to connect to the A/C halo adapter. Do Not Lengthen the White Halo wires. Only lengthen the red/black wires from the A/C inverter box.
- Clear sidemarkers use orange reflector as a template and cut out a clear sidemarker from flourescent drop ceiling cover, bought and a home depot. Use small amount of clear epoxy on backside of new reflector. Hold in place w/ clamps til dry.
- Put the 3 pieces of the headlight assembly and bake again for 20 minutes. Squeeze it all together and start attaching bulbs, screws, wire harness.
- Put back on Max.
 
Remove Bumper  Remove Headlights
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