Opening headlights – HiDplanet : The Official Automotive Lighting Forum


    sorry for a newbish thread but i got a question.

    my car ( 2000 lincoln ls ) has headlights that have grey glue. i have took them apart and did plenty of diy work to them. im doing a 2006 conversion and those will have the black rtv like sealant. im being told that those cant be opened. i have opened other headlights with black sealant and a dremel tool but someone is swearing that you can open the lights with the black sealant using the oven or heat gun like the grey glue. says they have done it plenty of times and they do have a bit of a side thing doing it for people over the web.

    anyone think they can chime in?


    grey or black

    “butyl rubber” seal can be soften by heating up(temp below pp-housing can handle)

    some maker use grey butyl rubber, some use black butyl rubber.
    so color of seal won’t mean much.

    but as you mentioned “rtv like” seal can’t be open with heat. well, they melt at higher temp,,but hosing will get heat damage before seal melt.

    i think those who insist “black seal can be heated and opened” talking about “black butyl rubber seal”


    yup, color doesn’t mean much here. i come across headlights using grey sealant, and headlight using black sealant, both can be soften by pretty much same amount of heat.

    it’s all about the material….

    look at my hid / lighting
    writings at stupidpig hid | facebook


    well, this might be possible but i feel some automobile manufacturers must be using different black sealants. i have gone at a set of lights today with a heat gun and the oven. they are 2000 lincoln ls lights but unlike my 2000 lincoln ls lights they have black sealant as opposed to what i call the grey putty like stuff. they barely softened at all.

    so, i have to say that myself and the person whos knowledge is in question must both be correct i guess.


    yes some are using silicone based seal that are not soften with heat easy within housing material temp rate.

    those one need to be physically opened rather than thermally open.


    all the newer dodges use this crap to seal their headlights & it’s a royal pain. it takes me 3-4 hours to open a set up & about another hour to re-condition the groves.

    it’s basically the same heat temp & process as opening the butyl sealant except you may end up having to re-heat the headlight as many as 10-12 times where i can get the butyl open in 1-2 cycles in the oven. i also use a heat gun on the high setting (keep it moving so the pp housing don’t melt) to really soften the rtv-like sealant up. although it doesn’t become gooey, it does get softer with heat.

    the main difference is that you end up trying to pick/ chisel as much of the rtv-like sealant out from around the lens with a screwdriver as possible before trying to separate the lens. then you’ll have to dremel out all the hard sealant from inside the grove you you can have a clean new bed to lay the butyl sealant into later on.

    the top is what the grove looks like after freeing the lens from it’s grasp. the bottom is what it looks like after cleaning the grove with the dremel & using the heat gun to re-shape & form the grove back as close to stock as possible. most headlights either have a rubber gasket or the bumper hides this area so it’s not too big of a deal.

    opening headlights - hidplanet : the official automotive lighting forum

    here’s two more examples
    opening headlights - hidplanet : the official automotive lighting forum
    opening headlights - hidplanet : the official automotive lighting forum

    john | kustom54lighting
    2008 jeep wrangler sahara jk / 3.5″ re lift, 35″ mtz’s on 20″ motometal 961’s (wife’s toy)
    1999 jeep cherokee xj / 6.5″ rc lift & 33″ mt’s (winter beast)


    haha, i feel i’m lucky to have a honda…….

    look at my hid / lighting
    writings at stupidpig hid | facebook


    i’m glad i only do work on one make/model of car. i got it down to a science and now retrofits are not a headache.

    typical mh1 setup – 4300k – mini gatling gun shrouds – 96 impreza wagon

    my hid retrofit pictures (customer cars)


    originally posted by taiden

    i’m glad i only do work on one make/model of car. i got it down to a science and now retrofits are not a headache.

    i only do one make “dodge, jeep, chrysler” for the same reason as i believe “it’s better to be great

    at a few things then to be good

    at many things” but unfortunately mopar decided to use the wrong sealant opening headlights - hidplanet : the official automotive lighting forum

    the good things is i use a lot of aftermarket housings which all use butyl so it’s not too bad.

    john | kustom54lighting

    2008 jeep wrangler sahara jk / 3.5″ re lift, 35″ mtz’s on 20″ motometal 961’s (wife’s toy)

    1999 jeep cherokee xj / 6.5″ rc lift & 33″ mt’s (winter beast)


    is the glue that’s not butyl really silicone? they do make silicone remover whick turns silicone into soft liquid goo. i wonder if it would work with that sealant? that would save time.


    how would you apply it deep in the groove?

    the early year lincoln ls has the grey stuff but the later does not. they even changed in the middle of the first year run so its a 50/50 no matter how hard to try to obtain a set with grey glue unless you look under the weather stripping and happen to see a bit of grey stuff popping out.

    Read more: Headlight Assembly What Size Bolt & Washer

    i had put a crappy set in the oven with the black stuff once and it did soften it to a degree but not enough to open the light without mangling it. i only gave it one run tho and i might have had better luck placing it in the oven multiple times. i dont like doing that nor using a heat gun. i would rather get it right the first time and have it all pull apart at once rather then twisting the surrounding pp attempting to pry at it multiple times.

    250 degrees for 8 minutes is the sweet spot. no reason to use lower temps and pull at it multiple times cause like i said, you run the risk of twisting and warping the surrounding pp.

    i guess i have one option and thats to try to contact fomoco ( yeah right ) and find out what sealant they use ( fat chance they will know!!!! )


    i called ford about it and they had no idea what i was talking about.

    does anyone know where to get grey butyl sealant?

    the nissan one is black.

    opening headlights - hidplanet : the official automotive lighting forum

    tl / zkw-r / osram cbi / 35w matsu / painted shields / gatling shrouds / led

    i raise your hid kit with a tl retro highbeaming blast


    opening headlights - hidplanet : the official automotive lighting forum

    tl / zkw-r / osram cbi / 35w matsu / painted shields / gatling shrouds / led

    i raise your hid kit with a tl retro highbeaming blast


    originally posted by cruisingjuicedandboosted

    i used the same stuff on my headlights…it’s crap. luckily i only did one headlight with it. it stays soft…it just peels right out. one day i noticed my headlight lens was falling out. avoid at all costs.

    the 3m windo-weld ribbon is the same consistency (only comes in black), it also doesn’t harden up like the hot melt butyl they use to seal up headlights. going to try to get my hands on some hot melt butyl, but i can’t find the gray in small quantities. might have to go with black.


    originally posted by thumper88

    originally posted by cruisingjuicedandboosted

    i used the same stuff on my headlights…it’s crap. luckily i only did one headlight with it. it stays soft…it just peels right out. one day i noticed my headlight lens was falling out. avoid at all costs.

    the 3m windo-weld ribbon is the same consistency (only comes in black), it also doesn’t harden up like the hot melt butyl they use to seal up headlights. going to try to get my hands on some hot melt butyl, but i can’t find the gray in small quantities. might have to go with black.

    damn. thanks for the info. good thing i didnt order yet. theres no way in hell im going to use black for my application..everything is silver/chrome/clear…hmmm might look like shes rockin mascara lol

    opening headlights - hidplanet : the official automotive lighting forum

    tl / zkw-r / osram cbi / 35w matsu / painted shields / gatling shrouds / led

    i raise your hid kit with a tl retro highbeaming blast

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Category: Headlights