DIY: Clear Corner / Black out housing mod / Halos

[yellow2000S/R]

DIY: Clear Corner / Black out housing mod / Halos (Brought up in the ChatBox)


There are 2 main ways to go with this mod. You would choose option 2 if you are also planning on blacking out the headlight housings similar to the ZXTuner housings.

I'm writing this based on memory of what I read on the old site and what I did while doing this to a Chevy Cobalt.


Tools Needed:

2x medium sized flat head screw drivers
1 tube of clear silicone
10mm deep well socket (possibly a 12mm as well)
14+" of extensions
Appropriate ratchet wrench for extensions/socket
Phillips screw driver
Black spray paint (if doing the black housing mod)
2 halos if you are adding them


To start:

Remove splash shields in both front wheel wells.
Remove the bolt at back of front bumper holding the tips to the fenders.
Remove 2 bolts on each side using 14+ inches of extensions that are behind/below the corner signals that you want to remove that hold the bumper to the fender.
(Undo harnesses for fog lights if equipped).
Remove 3 bolts across top of bumper that holds bumper to the header panel.
Remove various bolts and nuts from studs holding headlight housings to radiator support.
Undo the harnesses and pull the bulbs.



NOW



Option A: Removing corner only and leaving it like that (98 has all chrome, 99-03 is black plastic)

Take flat head screw driver and jab it at the back side of the amber piece breaking it into many pieces while being careful not to scrape the inside of the lens.
Then vacuum / shake out / blow out broken pieces.
Reverse removal procedure to reinstall.



Option B: Removing corner, adding clear piece from drop ceiling light covers, and/or painting housings black.

Preheat oven to 250*F
Put a headlight on a cookie sheet that is wrapped in aluminum foil (in case any glue oozes out, easier cleanup).
Once oven has reached temp, place 1 headlight in on the cookie sheet and set timer for 12-15 minutes (don't be scared, I've done it before).
After time is up, pull out light and place on counter on a towel (to prevent scratching lens)
Take 2 flat head screw drivers and put in between crack of lens and housing and start twisting sideways slowly and working your way around.
Eventually you will have the lens off. If at any point it starts getting harder, put it back in the oven for a few minutes.

Once the lens is off, you can pop out the amber piece in whole and use it as a template on a sheet of clear fluorescent light covers. Mark it out and take your time cutting it out so you don't go cracking it.

Scrape out old glue from where lens was pressed into housings. It is important to get as much out as you can to ease reinstall and for a clean look.

Paint the lenses / various reflectors black to mimic ZXTuner lights.

Wait for paint to cure.

You can also add the halos at this point using CA Glue (Hot Stuff, Zap, Crazy Glue, etc) to hold them in place.


Reassemble. Put a light bead of clear silicone around the housing where the lens fits in and then position lens and press in.
Once in, wipe off excess silicone with a damp towel or your finger to make it nice and "clean".

Wait for silicone to cure some and then put headlights back on rad-support reversing removal procedure.


Congrats, you have now completed the Clear Corner / Black out housing mod!

[yellow2000S/R]

Comparison pic of stock Cobalt headlight to the one I did for a friend:


STOCK:

http://z.about.com/d/cars/1/7/d/U/8_07cobalt_ls_headlight.jpg




Friends Headlight after removing cover over turn bulb and painting black.

http://www.endlessmotorsports.net/Gallery/CustomerCars/2007ChevyCobalt/TYLER%20COBALT/Working/DSCN1233.jpg

[TTFOWIA]

repped

[OGreaTFuzzY1]

X2

would help alot of nubs with photos though

~Fuzzy

[mellowness65]

photos are on the way when i finish one tomorrow, and 300 gets things done much quicker, but I think 275 will do best

[OGreaTFuzzY1]

i got photos of halo mod done -_-

~Fuzzy

[dbamaboy01]

thanx now i have something to do after I graduate

[powder]

When i cleared my headlights out and painted them i also painted the bottom portion of the reflector. It looks sleeker imo. I'll see if i can find pics.

[OGreaTFuzzY1]

you betterz

~Fuzzy

[powder]

Headlights up close:
http://i120.photobucket.com/albums/o189/powder006/IMGA0026.jpg

Headlights on the car:
http://i120.photobucket.com/albums/o189/powder006/P7160152.jpg

[OGreaTFuzzY1]

smexy

~Fuzzy

[corby_baby]

powder thats the first pic i have seen of your car hahahah

[pdwighty]

so can you break the reflector and vacume it out without taking out the light (or atleast without baking the light???)

[droptoutzx2]

i used a heat gun to do mine took a lil longer but no worries on melting the lens

[DaviDawg]

did mine over memorial weekend. i just wanted to share here too. thanks guys
original post here http://teamzx2.com/showthread.php?t=2578
before
http://i298.photobucket.com/albums/mm254/davidawg/zx2%20pics/DSC00669.jpg
after
http://i298.photobucket.com/albums/mm254/davidawg/zx2%20pics/DSC00680.jpg

[corby_baby]

looks a brazillian times better

[ZX2 Sleeper]

i used a heat gun to do mine took a lil longer but no worries on melting the lens


what heat setting did you use. example:medium, 3/4, 1/4. FULL BLAST! lol

[conquest-king]

here is a pic of mine done.

[transatlanticism]

If I take the amber reflector out of my headlight, will my turn signals still be yellow, or will I need to buy amber bulbs? Is it legal to have white turn signals in the front? I would prefer them to be white, but not if I could get a ticket for it.

[reinkezx2]

i beleive the urn signals have to be amber but u could just put amber glazed bulbs in it not worth a ticket

[capitalcrew]

They will indeed be white without the reflector. White turn signals are illegal. Amber bulbs are cheap.

[DaviDawg]

i took out my amber reflector and the bulbs were amber on my car. pull'em out and check. its easy to check. open hood, twist bulb socket and pull out, check.

[kln5014]

I think I paid like 3 bucks for 2 amber bulbs..they are number 194

[bigperm5901]

Once the lens is off, you can pop out the amber piece in whole and use it as a template on a sheet of clear fluorescent light covers. Mark it out and take your time cutting it out so you don't go cracking it.


do you have to replace the amber reflector piece with fluorescent light cover.and if so were would you buy them thanks.

[droptoutzx2]

what heat setting did you use. example:medium, 3/4, 1/4. FULL BLAST! lol

high at first to melt it some then medium

[yellow2000S/R]

Once the lens is off, you can pop out the amber piece in whole and use it as a template on a sheet of clear fluorescent light covers. Mark it out and take your time cutting it out so you don't go cracking it.


do you have to replace the amber reflector piece with fluorescent light cover.and if so were would you buy them thanks.

Get the covers from either Home Depot or Lowes. Wal Mart might have them also, as should most larger hardware stores / light stores.

[skyhighron]

what about the little round cover inside the light that goes over the bulb? would it look better without it or should i keep it?

[Buster]

The wires should remain attached to the car.

Just bake the housing.

[yellow2000S/R]

what about the little round cover inside the light that goes over the bulb? would it look better without it or should i keep it?

That cover cuts off light and somewhat reflects light back from the front of the bulb. If you didn't have that cover, I'd imagine that it would cause a huge hot spot and blind oncoming traffic as well.

[pdwighty]

Option A: Removing corner only and leaving it like that (98 has all chrome, 99-03 is black plastic)

Take flat head screw driver and jab it at the back side of the amber piece breaking it into many pieces while being careful not to scrape the inside of the lens.
Then vacuum / shake out / blow out broken pieces.
Reverse removal procedure to reinstall.




How long should this take... Day project or 1/2-1hour project?

and how hard is it to get the vacume to suck it up.. in anotherwords is if i could break the amber piece without taking light off car would it be hard to vacume out?

[yellow2000S/R]

How long should this take... Day project or 1/2-1hour project?

and how hard is it to get the vacume to suck it up.. in anotherwords is if i could break the amber piece without taking light off car would it be hard to vacume out?

I've never done the break up and vacuum process so I couldn't tell you. I've just read about people doing it that way in the past.

[MellowedZX2]

With breaking the Amber you have to be WAY CAREFULL about punching the screw driver through the lens, and it works but is a PITA.

Joel

[VJ87]

I'm going to be trying a projector retrofit and wanna do the halo thing. As far as wiring them goes how do i get it to where they come on with dome light. Then stay on when i put key on on and activate the accessory live wire. So they stay on with stereo and are always on? Thanks.

[Nismo]

I'm going to be trying a projector retrofit and wanna do the halo thing. As far as wiring them goes how do i get it to where they come on with dome light. Then stay on when i put key on on and activate the accessory live wire. So they stay on with stereo and are always on? Thanks.


Lots of wire and a few relays. I think getting that to work is a bit much. I'd say just wire them up to a accessory fuse and call it a day, that way with the key on, they're on.

[VJ87]

Yup thought about that too. Ill probably just do the accessory, and thats the easy one lol. I'm trying to motorize the vertical aim adjuster right now.

[VJ87]

Something crossed my mind Does when my room fuse blew i had no stereo or dome light. Meaning if i tap into this wire i think ill have halos when dome light's on and will stay on, correct me if im wrong.

[1981gMachine]

http://a37.ac-images.myspacecdn.com/images01/64/l_1206a6b65530b7170b5973d3558e034c.jpg

[VJ87]

Is there anywhere where you can buy just the lens by itself new?

[ilarson007]

Good mod, but how do you keep the headlights from melting and or warping. My friend was talking about a guy who tried it with his Civic at like 165 degrees and completely screwed the lights.

[mellowness65]

then civic lights are fail, i had to use over 250 to get my glue to think about coming off

[DaviDawg]

on the old site, nismo said to use 275 degrees iirc.

[VJ87]

I used 250F 17 mins one at a time.

[mellowness65]

yea i think i used 275 for like 8

[00zx2s/r]

mine isn't doin shit... I tried 250 for 13 minutes, then tried 290 for 5, and now i'm keepin it in 300 for 15 minutes... the cream adhesive is over flowing on mine (from stock) so it's hard to fit a flat head inbetween (especially since it wont melt...)

[Nismo]

I wouldn't feel comfortable putting a headlamp in the oven at 300. I've done it once before and it wasn't pretty.

The glue also isn't going to melt. Just soften. You should be able to find some part of the lens/base that isn't overflowing with glue and stick a flat head in there. I always use 3 different sizes to get started. Then once I get it apart enough to get my fingers in there I yank it apart.

[yellow2000S/R]

Just be careful that you dont pry too hard at the corners where the outter turn signals are. The way the plastic on the lense goes back in, you could easily snap it. I know I cracked the edge the 1st time I did them because I didnt know.

[00zx2s/r]

Eh, 300 worked at I got em done! I like em!... I think... lol. Idk if I should have painted more black or if it looks good now...

Before:
http://i22.photobucket.com/albums/b341/Pepsi_suks/100_7056.jpg

http://i22.photobucket.com/albums/b341/Pepsi_suks/100_7057.jpg


After:
http://i22.photobucket.com/albums/b341/Pepsi_suks/100_7068.jpg

http://i22.photobucket.com/albums/b341/Pepsi_suks/100_7058.jpg

http://i22.photobucket.com/albums/b341/Pepsi_suks/100_7060.jpg


What do ya think?

[yellow2000S/R]

What paint did you use? Did you scuff the plastic any?

[00zx2s/r]

black motor high temp paint from napa...
No i didn't scuff or nothing... I was kinda in a hurry since i had to leave for work just minutes after this was done (which I regret...)

[sinzx2]

i still have yet to do this although i have been meening to do it since i joined the site but with red maybe...any thoughts?

[DaviDawg]

red? i doubt it'll look good but its your car.

[oxfordwtZX2]

Did this to my Mustang tail lights. Came out REALLY great, and didn't hurt the light out put. Would it work on our tails too ya think? I like the look. I'll be doin this really soon. This week. Inner lights done too? Same way? I have a great heat gun, if that makes a difference....

[oxfordwtZX2]

Was wondering.....how would this look in gun-metal? I got the paint already, and it'd match my wheels pretty well.....

[mellowness65]

i still have yet to do this although i have been meening to do it since i joined the site but with red maybe...any thoughts?

that wouldn't be bad if it was your car's color

[capitalcrew]

Why does everyone paint the outside of the housing.... :shakes head:

[1981gMachine]

Why does everyone paint the outside of the housing.... :shakes head:

Mean the inside of the lens?

I didn't, I do need to brush paint the bulb holder since it's white.

http://a112.ac-images.myspacecdn.com/images01/114/l_4ce825a73bbda95ff9efaab3b9a5aacf.jpg

[capitalcrew]

Lens, yes.

I mean, by all means paint it black to match the zxtuner lights but paint the inside. You've got the lens off anyways..

[00zx2s/r]

I painted the outside because I was having serious issues getting the cover off... But one day here i'm gunna try and paint thin it off and redo it... And anybody know how to "touch-up" the headlights so they're not so scratched and fogged?

[yellow2000S/R]

I painted the outside because I was having serious issues getting the cover off... But one day here i'm gunna try and paint thin it off and redo it... And anybody know how to "touch-up" the headlights so they're not so scratched and fogged?


I did my buddies Civic... my way.

400 wet till everything is off the plastic lens... consistent white color. No yellow-ish left behind from clear or whatever the factory coats them in.

Followed by 600, 800, 1000, 1500, and finishing with 2000. Then hitting it with ScratchX, finishing with Meguiars PlastX. Still look great but its only been 5 months or so.


I wish I would have taken a before and after of the full front along with lighting comparisons. Light output was greatly improved and the beam "pattern" wasn't just a glow anymore.
http://www.endlessmotorsports.net/Services/BodyWork/HeadlightBuffing/Comparison.jpg

[00zx2s/r]

Wow! That looks amazing! Thanks for the "write-up"