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  1. #1
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    HOW TO: Strip down an S15 Headlight!

    The method I used here caused no clips to snap, no plastics to melt, and generally, no damage AT ALL to the headlight unit.

    First, preheat oven to 90'c and arrange the shelves so that you can squeeze your headlight in. I used tin foil to prevent tray imprints on my headlight, and also to prevent direct metal contact, and meltage! I did mine like so:


    Whilst this is happening, ensure you remove the wiring loom from the rear (it all unclips pretty simply), as a melted wiring loom would be a bad start to the day. Also, around the back of the unit are 5 small screws holding the lens to the big black housing. Remove them!

    Once oven is up to temp, slot the headlight in, ensuring that it is not touching any sides, and preferably lense upwards. This prevents any chance of anything staining the lense when it gets hot. (Yes it was a tight fit in my oven, but worked!):


    Now, make yourself a nice Yorkshire Tea and wait for 10 minutes.

    Once your ten minutes are up, the headlight unit itself will feel pretty warm. But not too hot to hold. (Just make sure you dont touch any metal bolts with your hands... Also the projector part of the unit is solid metal.. so take care!

    You can then proceed to find a small gap to stick a blunt knife into and pry yourself a finger grab:


    Once you've got a bit of a crack appearing, then you need to apply some brute force as the glue is out of reach of the knife. You really do have to get two hands on it and pull like mad. I started with the full beam side as this was the easiest to get a hold of:


    Keep on pulling and it will peel away as the plastic is still soft. (the black plastic will be a lot softer than the lens. use that to your advantage.


    And hey, Voila! One times, split headlight:



    The remainder is pretty simple to take apart using the variety of 8mm bolts and screws holding stuff in place.
    The projector lamp and full beam however need to be fully unscrewed using them 4 massive heads on the back of the unit. Once they're fully undone, it'll just fall out.


    Fully disassembled:


    Enjoy!

    3 Years, 52,000 miles, Multiple Collisions, Two Write Offs, One Severe Flood creating the 3 cylinder SR15DET for a week. And now its scrap.
    Now that's what I called a daily drive!

  2. #2
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    Cool, always wanted to do this so I can get to the screen from inside, as this is a good way to get the yellow tint out from sun damage. Never had the balls to do, but seeing that you've do it ok I "might" give it a go.

  3. #3
    meddler's Avatar
    meddler is offline It's not easy being a green text speak nazi
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    Awesome work.
    Never let the truth get in the way of a good story

    If you use text speak on this forum you WILL get an infraction.

    Believe it or not, what has a 'h' in it and you is not spelt 'u'


    Forum Rules | For Sale Rules | Useful Threads | IRC Chat channel is now closed

    Thought for the day: Get a spell checker!!! READ THE F!@#ING RULES.

  4. #4
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    It's like you used all the photos I took but never made the guide!

  5. #5
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    good on ya, a lot of us have been waiting for someone to do it first as we dont want to wreck out lights

  6. #6
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    Haha no problem guys I just so happened to have a spare headlight so it was all good

    Useful Links section?

    3 Years, 52,000 miles, Multiple Collisions, Two Write Offs, One Severe Flood creating the 3 cylinder SR15DET for a week. And now its scrap.
    Now that's what I called a daily drive!

  7. #7
    craig8585 is offline I'm so cool, I have my own fan thread :p
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    Do you want a sticker too!?

  8. #8
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    good work! may use this one day myself

  9. #9
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    Quote Originally Posted by Jay View Post
    good work! may use this one day myself
    Do it mate! its easy!

    Quote Originally Posted by craig8585 View Post
    Do you want a sticker too!?
    Yes please!
    And one of those things you RAF boys do to get promoted.. hmm.. what's it called again? Starts with a B.. ends in a Job.. hmm.

    3 Years, 52,000 miles, Multiple Collisions, Two Write Offs, One Severe Flood creating the 3 cylinder SR15DET for a week. And now its scrap.
    Now that's what I called a daily drive!

  10. #10
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    HOW TO: Strip down an S15 Headlight!
    @4ndy_hunt
    good work mate, tried this last year using a heat gun, did not go to well. May give it another go. Only problem is 90'c is lower than 1/4 of a gas mark which could make things intersting.
    [SIGPIC][/SIGPIC]

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