87-91 Clear headlights - DIY
06-16-2013, 02:52 PM
#1
Just call me sean. Really
Thread Starter
87-91 Clear headlights - DIY
So most of the people here with an 8th gen have seen the headlights I have on my truck. A lot of people ask, I've been running them for 8 months this way, and I guess now I can actually make a thread to let you guys in on the secret... It will be very text heavy, as I've lost the 3 pictures I took while in the process of making.
To start with, get the lenses off the housing. If you have the original heads still on the truck, it's retarded easy. Take a small flat head and pry it apart. I started right in front of the adjusters on the top of the housing. Once you get it starting to separate, use a big flat head or something else just to hold it there while you work your way around the light. I only had to work on the top and the side that faces the grille before the old sealant just gave in.
Next comes the fun part! I'm sure there are better ways to do this, but this is just what I did. I used a dremel with a cut off wheel to make a slit in the lens as close as I could to the chrome trim. The dremel WILL melt the plastic, so just use it to get the hole started. Then I used a hand held hack saw to continue around. It's a pain in the ***, but it's worth it.
Once the lens plastic is cut out, you're about done. I used Lexan (home depot, Lowes, etc, have it) and had them cut it for me. The housings on these are 99% perfect square so it was very easy for them to cut it.
While you're still at the store, flip the whole lens/trim thingy around so you can look through it from behind. Inside there is a lip that runs on 3 sides, that's where I put the Lexan. So the lens is set back about a half inch from the trim, as opposed to flush like stock.
After you have the lexan sitting on that ledge inside, use CLEAR silicone to seal it in there. It took me a couple tries to get the sealant in every little nook and cranny, but I did get it and haven't had any moisture inside since.
As a test for the seal around the lens, I set the piece chrome trim down, and poured water on the lens and let it sit for 15 minutes. After 15 minutes none had leaked thru, so I was sure they were water tight. Pour out the water, and let dry obviously
This is optional - in the reflector of the headlight, above and below the reflector are off white colored areas. I painted the lower one black, and I think it looks much better. So now you just see black and the reflector for the light bulb.
Finally, after you are sure the lexan is sealed very well to the trim bezel thingy, re-attach to the truck. I used 1 minute instant gasket maker, the stuff for diff gaskets, tranny pan gaskets, etc. Run it along the 4 sides of the trim bezel, and then attach back to the truck!
And suddenly, you have an old Ford with modern looking headlights!
And of course, I assume no liability for this. This makes the housings unable to pass a DOT inspection, the beam pattern gets much more focused, etc. They would now be classified as "off road use only."
I'll answer any questions you guys have, and to add pictures where ever it seems like there is confusion. Just want to see more people running these, and even improving on it!
To start with, get the lenses off the housing. If you have the original heads still on the truck, it's retarded easy. Take a small flat head and pry it apart. I started right in front of the adjusters on the top of the housing. Once you get it starting to separate, use a big flat head or something else just to hold it there while you work your way around the light. I only had to work on the top and the side that faces the grille before the old sealant just gave in.
Next comes the fun part! I'm sure there are better ways to do this, but this is just what I did. I used a dremel with a cut off wheel to make a slit in the lens as close as I could to the chrome trim. The dremel WILL melt the plastic, so just use it to get the hole started. Then I used a hand held hack saw to continue around. It's a pain in the ***, but it's worth it.
Once the lens plastic is cut out, you're about done. I used Lexan (home depot, Lowes, etc, have it) and had them cut it for me. The housings on these are 99% perfect square so it was very easy for them to cut it.
While you're still at the store, flip the whole lens/trim thingy around so you can look through it from behind. Inside there is a lip that runs on 3 sides, that's where I put the Lexan. So the lens is set back about a half inch from the trim, as opposed to flush like stock.
After you have the lexan sitting on that ledge inside, use CLEAR silicone to seal it in there. It took me a couple tries to get the sealant in every little nook and cranny, but I did get it and haven't had any moisture inside since.
As a test for the seal around the lens, I set the piece chrome trim down, and poured water on the lens and let it sit for 15 minutes. After 15 minutes none had leaked thru, so I was sure they were water tight. Pour out the water, and let dry obviously
This is optional - in the reflector of the headlight, above and below the reflector are off white colored areas. I painted the lower one black, and I think it looks much better. So now you just see black and the reflector for the light bulb.
Finally, after you are sure the lexan is sealed very well to the trim bezel thingy, re-attach to the truck. I used 1 minute instant gasket maker, the stuff for diff gaskets, tranny pan gaskets, etc. Run it along the 4 sides of the trim bezel, and then attach back to the truck!
And suddenly, you have an old Ford with modern looking headlights!
And of course, I assume no liability for this. This makes the housings unable to pass a DOT inspection, the beam pattern gets much more focused, etc. They would now be classified as "off road use only."
I'll answer any questions you guys have, and to add pictures where ever it seems like there is confusion. Just want to see more people running these, and even improving on it!
06-16-2013, 04:20 PM
#3
Just call me sean. Really
Thread Starter
You could... but why? They make housings for the 92-96 which would be a far better plan. I only did this because there are no aftermarket lights for the brick nose
08-15-2013, 09:43 PM
#4
Just call me sean. Really
Thread Starter
Picture time! In the process of making this set for a member on here, just in the waiting phases...
Starts like so:
Which then progresses into this!
This one is kinda confusing, but due to the shapes inside the lens housing, some very fine trimming is needed of the lexan piece
Put the lexan in, and now the seal...
Most nerve racking part, as it's hard to do this and keep it clean! Nature of the beast, the seal is going to be seen from one angle due to trim only being on 3 sides of the housing.
Another shot of the insides and how to seal things in
Starts like so:
Which then progresses into this!
This one is kinda confusing, but due to the shapes inside the lens housing, some very fine trimming is needed of the lexan piece
Put the lexan in, and now the seal...
Most nerve racking part, as it's hard to do this and keep it clean! Nature of the beast, the seal is going to be seen from one angle due to trim only being on 3 sides of the housing.
Another shot of the insides and how to seal things in
The following users liked this post:
Sulli8888 (07-05-2015)
10-13-2013, 06:27 PM
#6
Austinn54
okay.. so, not too sure I follow all of this. a couple of questions. 1) did you buy a new lens cover or just clean it? (if cleaned, what did you use?) 2) what trimming is needed on the lexan piece?
10-13-2013, 09:07 PM
#7
Just call me sean. Really
Thread Starter
2) Just a tiny little trimming of the lexan. Just 2 notches basically, so it sits flat inside the housing. It's hard to explain, but if you attempted it, you would see what needed to be done.
Trending Topics
10-13-2013, 10:33 PM
#10
Just call me sean. Really
Thread Starter
I walked into my local lowes and bought it. They have the equipment to cut it, so I went in with the whole truck lens/trim piece and said cut it so it fits in here lol. Then I just have to trim it a little and seal