JDM headlight project.

What’s up dude’s?
I got tired of looking at my driver side yellowing and leaking headlight. So I decided to do something about it. Lucky for me I had a set of USDM’s to put in place while I take my time with the JDM’s. I made the mistake of using a different kind of sealant, it was a brownish red color and I wish I had never thought of using it. It ended up just hardening and flaking causing a bunch of water leakage. So I turned the oven on removed all of the clips, metal hangars and bulbs. placed it into 300 degree’s of heat for 2 min and managed to remove the lens without breaking it.

Next was to remove all the gunk that was dried up in the main housing, took me a couple of hours but they ended up clean again. This time I used the gray sealant from Auto Zone as its the same stuff as Honda bond only cheaper. And at least with this tube you get a funnel tip to put the right amount without getting my fingers all tacky. I then cleaned out the fog-light bulb as it has turned kind of brownish instead of being yellow. Thanks to Kyle (Knowledge420) for hooking me up with the donor lens. The replacement lens is next to perfect. I even used the main reflector unit from the donor and placed it into my headlight.
Finally I joined everything together, put the clips back on and put it back into the oven for 2 min and Voila, she is sealed and ready to be put back on.

Now I have another dilemma. Since I went back to USDM I also had to change out the wiring harness, well instead of cutting wires again I decided to be smart and buy a Password JDM adapter harness (arriving in a couple of days). I could just drive to Pico, my home town and pick it up, but hey I’m a LAZEE Mexican.

So here’s a couple of pics I snapped.
Thanks for taking the time to read. If you have any questions don’t hesitate to ask.

Before

After, don’t let the blue reflection throw you off, both headlights have the same bulbs.

How they looked before replacement. Well, you really can’t see the yellowing but its there.

Next will be to Paint my mouldings, mirrors and replace my front bumper with a 92-93 (courtesy of a real brother, you know who you are) in the coming months. And will be lowering it and getting it clay bared, polished and then finally a waxing.

I also do have an extra lens and some inner housing parts if you would like to buy them. I don’t have a fog bulb though, the original was cracked. I do have the clip and spring.

looking good anthony. good job:rockon:

dude let me have the other light :angel:

Lookin’ GOOD! :rockon:

Its just the lens, Leo. I already tossed the housing in the trash. The mounting tabs were broken off and the bottom had its brackets torn off from the housing, so there were huge holes. the light wouldn’t even mount in the car.

nice man i havent seen your DA in awhile lookin good :rockon:

What lip is that? I have been debating switching to a 93 bumper, because my car IS a 93 with a 91 bumper. But the 91 is growing on me a little.

90-91 OEM Optional lip… very rare and hard to find.

[QUOTE=DAnthony9;2120910]Its just the lens, Leo. I already tossed the housing in the trash. The mounting tabs were broken off and the bottom had its brackets torn off from the housing, so there were huge holes. the light wouldn’t even mount in the car.[/QUOTE]thats fine, i need it to make a mold for my project :smiley:

Hey! Can one of you brutha’s hook me up with some THIN SIDE MOULDINGS??? Don’t have to be new, as I only have like a Benji to spare.:angel:

JDP Engineering sells the OEM Opt. lip copy. I think its made of fiberglass though. The OEM originals are made from plastic.

what was the process u used to taking apart your headlights and re-installing the lens?

You bake it in the oven for about 10 minutes at 250 degree heat then slowly pry the lens apart using a flathead screwdriver or a chisel…

Nice job on the lights! I personally don’t like the oven method and have not had very good experiences with heatguns or hairdryers either. The best method that I have found is boiling a couple large pots of water and getting some large aluminum disposable food trays (the kind used for catering) and putting the lights in them and pouring the boiling water in/around them. Couple layers of latex gloves so you don’t burn yourself and a flathead screwdriver or two and they come right apart (works on taillights, too).

Wow, that’s a new one! Seems messy but whatever works. I find the oven method to be very simple… did two sets without any problems…

I wouldn’t be surprised if people get different results with different types of ovens (particularly gas vs elec), so that may be a factor with some people having good/bad luck.

i would never put a set of headlights in a gas oven. when it comes to light lenses, burning vapor vs heated coil? the vapor has got to leave some sort of remnant.

welps…i have an electrical oven…so i’ll be ok.

nice job… does anyone know what bulbs to buy with the password jdm harness?

I beleive the Password JDM harness is a 9004 (USDM) to H4H (JDM)conversion. So youd need H4H bulbs.