Ok, a few of you want to know how it is done.......
First of all, do you have an electric oven that is clean and large enough to put the entire headlamp inside, with the door closed?
If so, continue. (Using a hairdryer is just a pain)
Remove the headlamp from the vehicle. Two bolts on top, one at the rear. (10mm or 12mm, can't remember right now)
Disconnect the large power plug running to the lamp. (Squeeze connector, it pulls directly back towards the rear of the vehicle)
Now with some force, pull the entire assembly forward and up slightly. (Don't worry if the lamp gets caught on the bumper, just push down slightly with the palm of your hand on the bumper)
Once out, find a nice clean work area (Kitchen table works best) put down two clean towels, and gab a third older towel.
Walk to your oven, pull all the trays out, and anything else in there, put a tray on the lowest level, put an old teatowel on the bottom tray/shelf making sure it does not touch the floor or sides of the oven. You will be placing the headlight onto this towel.
Set oven for 60 degrees C (If you have an oven that only starts at 100 degrees C (Like most) just turn the dial to where 60 degrees C might be and you'll notice the oven turns on.)
Close door, clean hands of all grease and dirt, then go back to kitchen table
Remove the two large round covers on the back of the lamps, put the side. Remove the bulbs (H7 low beam, H1 high beam) put them to the side, wrapped up in tissue or cloth.
Using a Phillips head screwdriver, remove the top mounting bar (4 screws hold this in)
Now most important (Otherwise you WILL break your lights if not done) remove this single Phillips head screw, indicated by the green arrow. (Above the low beam hole)
Once done, remove the indicator lamp by just unscrewing it.
Now, turn the lamp over in your hands and familiarise yourself with all the 'tags' that look like they hold the clear section to the black section. There are plenty of them. A small flat headed screwdriver will help pry the tags over the bumps sticking out of the clear sections.
Ready? Is the oven up to temp? (You should be able to place your hand in the oven, feel it's warm to hot, but not uncomfortably hot that you can't keep your hand in there.)
Shove the entire lamp assembly into the oven. on top of the tea towel. Clear side facing up. Make sure NO part of the plastic is touching any metal part of the oven, it's walls or door.
Close door, set timer for roughly 15-25 mins.
Keep checking the oven to see and smell any issues. When it's about done, you will smell first plastic, then a rubber smell. As soon as you smell warm rubber, remove the lamp assembly with the spare towel you have (It's going to be uncomfortably hot to handle)
Leave oven on (Because you may need it)
Quickly get to the kitchen table, then carefully pry each black tab up slightly whilst pulling the clear covering apart from the black housing.
The black 'goop' should pull apart on both sides. DO NOT allow this goop to contact the lamp on the insides. (If need be, a stanly knife will help 'cut' the goop.)
If you find it very hard to pull apart, shove the entire lot back into the oven, bake it a bit longer. (All you need to do is heat the goop.)
Keep checking the temp of the assembly by putting your hand on it. It should be hot to the touch, not melting. Bit like the heat of the lamp on a hot summers day.
Ok, you have the lamp apart.
The chrome rings and chrome assemble will be screwed to the clear front section. (Two small Phillips head screws)
Unscrew, then put the clear section to the side.
Now the chrome section has two rings, one cover plate and the indicator lens, all which unscrew with a Phillips head screwdriver.
Now it's up to you what you wish to paint, what colour, and how to paint it.
I used Automotive engine heat proof paint, good for 540 degrees C (1000 F) Metallic Charcoal in colour. (Flat finish, no gloss)
One 300g can did all four lights.
Now, prepping, make sure no fingerprints or marks are on the chrome. I cleaned with RO water (I have a 6 stage Reverse Osmosis water system, due to our crappy water here) and a very clean cloth (Brand new microfiber, $4 for a pack of 6 at local car store)
Warmed the chrome up in the oven for a few minutes (Warm, not hot) took outside and sprayed several coats first. Let sit for two hours, then a couple of more coats.
I let them sit inside for 12 hours, then heat cured them with a hairdryer. (Holding them, heating them up untill you can smell the paint,)
It is important you cure the paint BEFORE assembly, otherwise misting/clouding can occur inside the lamp when it heats up during operation.
Let them cool down, assembled the now painted pieces back in reverse order.
Now, for the fun bit. Heat the oven back up, put the clear lens section with the attached painted but AND the black headlamp assembly into the oven and bake at 60 degrees C for 10-15 mins.
Pull them out, and push them together. May need towel again for this. Make sure ALL the black tabs have been pushed over the clear tabs.
Screw all screws back in, fit bulbs, fit back into vehicle.
Done.
Fog lamps, almost the same, but they have a different kind of 'goop' that holds them together. It requires about 80 degrees C oven temp for around 35-40 mins.
I am only offering this as advice if you wish to follow it. Please do not hold me responsible for any damage or problems caused if you forget the lamps in the oven, or mark the plastics.
Hope this helps. 8)
