Items needed:
Krylon Fusion-Matte Black (sticks to plastic so you dont have to do prep)
Krylon Clear
Silicone sealant
Two or three butter knives (classy I know)
Oven (timer helps)
Mechanics Gloves (helps get the hot headlight out of the oven and handle it while it is still hot)
Headlights would help also.
Procedure:
I started with an extra set of headlights; however, if you do not have an extra set, I would suggest this be done on a long Saturday or even a full weekend (the silicone sealant is supposed to cure for 24 hours).
1.) Remove the front fascia
A.) Remove Grill (6 pushpins)
B.) Remove Plastic Fender Cover
i.) Four pushpins across the top
ii.) Three 10mm bolts (one in the center and one under each
headlight)
iii.) Two 10mm bolts on the underside of the fascia
iv.) Three clips on the inside of the fender cover on each side (these
are more easily accessible through the wheel-well)
v.) Before you yank on it to remove the plastic cover, there are two
clips inside the fender right beneath the light (I just pulled on it
and they broke...but does not seem to be a problem considering
the other things holding the cover on)
C.) Remove plastic support of plastic fender cover (two 10mm bolts)
2.) Remove Headlight Assembly
A.) Unbolt the headlight assembly (two bolts per headlight in addition
to the one for each headlight that was removed with the fascia)
i.) One is on top (easy to find)
ii.) One is under the headlight assembly
B.) Gently slide the headlight assembly in toward the middle of the vehicle (there is a clip that helps hold it behind the side panel) and pull out
C.) Remove bulbs (Hi's and Lo's) from the back of the headlight
assembly and two bulbs from the turn signal portion
3.) Cooking Time....
A.) I baked one headlight at a time at 220 F for 8-10minutes
B.) Pull the headlight out (it will be hot so use gloves)
C.) Using the butter knives, edge under the plastic lip of the lens. It
should begin to clear where the knife separates the sealant from the
plastic.
D.) Repeat the above process and bend the clips. Now that the top seal
is opened, slide the butter knife inside the lip and down the edge of
the plastic lens, then gently pry up (this needs to be done slowly or
you will break or scratch the lens). Reheat once the sealant is no
longer pliable. Do this for both the headlight and turn signal lenses.
Pics http://www.flickr.com/photos/36097466@N08/?saved=1
4.) Paint. I would note here that the chrome on the headlights likes to
come off if masking tape is used, so tape on the sides to avoid
removing the chrome (saranwrap to cover them helps). Spray light,
even coats to desired darkness, then finish with a clear coat.
5.) ReAssembling the headlight...Note: the turn signal is painted on the
outside (to get rid of the orange) so make sure it is dry before trying to
bake it.
A.) Reheat the oven, bake headlight without lenses (first time) at same
temp as before. Gently press the lenses back into place (This took
me at least four times for each lens. I suggest doing the headlight
clear lens first).
B.) Press and hold firmly until headlight cools after the last of the lens
clips are able to close of the plastic tabs
6.) Reseal...Apply silicone sealant to all sides of the lens and in between
the lens and assembly. Wipe away excess.
7.) Re-install headlights and replace bumper and fascia
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