Carcrazygts2

No originally I was going to be using the square D2S projectors. I'm using the flat sided round apollo shrouds

blupupher

iTrader: (2)

I almost got the D2S when I did mine, they were only $20 more at the time with the discount code, but did not want to cut up the housing.
Yes the D2S is a better light than the H1, but is also a lot more work.
Interested to see how it turns out.

DrillRig52

Sub'd

Carcrazygts2

From doing some initial test fits with a stock 03 F150 headlight housing there wont be any cutting or trimming. The stock headlight I tested with is almost identical to the 03 Harley's I'll be using minus the extra reflector in the front.

blupupher

iTrader: (2)

So the D2S fit in the 9007 bulb opening?
The H1 Mini has a 23 mm diameter, the D2S has a 32 mm diameter. I know I measured the opening when I did my bulbs, but don't remember the number off hand (I want to say 27mm??). From what I remember when I put the H1's in, there was not a lot of space in the opening.

Carcrazygts2

The threaded shaft barely fit. I will have to trim to get the alignment plate correct and the nut to tighten everything together.

Carcrazygts2

First lamp just made its way into the oven. This process is going to take a little over a week. I'm still waiting on a few things to come.

Carcrazygts2

[MENTION=145518]blupupher[/MENTION] [MENTION=45175]BrowningSCrew[/MENTION]

Got my corner lamps opened up with no problems. Using 220 degrees to get the permaseal to seperate. Now onto the headlamps and after an hour of being in the oven at 235 degrees the permaseal hasnt budged. I have not left the headlamp housing in the oven for more than 15 minutes at a time for fear of warping it or damaging the lense.

Any thoughts fellas?

blupupher

iTrader: (2)

I think I did mine @ 250° F for 10 minutes. It can be a pain to get it started, but once you do it is easier.
I have a plastic trim tool that I was able to use to get it started. You need to be quick too, it cools fast. Both headlights I had to put back in to finish getting them apart.
Some headlights use a different sealer and will soften at different temps. I have read that most headlight assemblies are safe to around 300° before you start to soften the lens material.

Here is a video from TRS, they say 270 for 7 minutes for butyl sealed headlights, and even 285 for 23 minutes for permaseal headlights (which yours may be).

rcruz3568

I had mine in for 10 mins on 250. Took a flat head screw driver and instead of prying the lens I put the screw driver in the crack and twisted. After I got a gap they came apart easy. Had to wear gloves... Everything was to hot to hold lol