splitting open new headlights

[Hammie]

I did the joey mod on my factory headlights already but was wondering, would it be more or less of a bitch to split open some Brand New housings vs lights with thousands of miles on them?

[Hugh@EuropaParts]

I did the joey mod on my factory headlights already but was wondering, would it be more or less of a bitch to split open some Brand New housings vs lights with thousands of miles on them?

I don't think there would really be a difference... I do think lights that have been opened tend to be easier to open again... (less time "baking" them with the head gun)

[Hammie]

I agree but I was thinking of headlights that were never opened, not the ones I have now.. IF I dont find some cheap oem xenon housings I'm Leaning towards modding some chrome E-codes. Save me a few bucks from buying S4 lights if I'm going to open them anyway

[AutoUnionLov3r]

Good point there Hammie. However I think it would ultimately be the same difficulty new or old, just depends on if you want to re-use your already "joey'ed" headlights or not. The ecode route, since ecodes are not OEM, might be a little easier to work with due to, like you said, the "new" housings and also who knows how tight they're sealed, (being not OEM).

[Duchenbagen]

Good point there Hammie. However I think it would ultimately be the same difficulty new or old, just depends on if you want to re-use your already "joey'ed" headlights or not. The ecode route, since ecodes are not OEM, might be a little easier to work with due to, like you said, the "new" housings and also who knows how tight they're sealed, (being not OEM).

E-codes are OEM headlights. Just not N/A spec.

[Kwarner]

E-codes are OEM headlights. Just not N/A spec.

This. Only "e-codes" that are not OEM are the Depo ones.

[B6A4Dave]

I kinda wanna see how other people pulled theres apart...I feel as though mine was way too awkward and time consuming and damaging...I heat gunned every 3-5 inches and had to pry the plastic back like 90*....there has to be a better way..

[Kwarner]

I kinda wanna see how other people pulled theres apart...I feel as though mine was way too awkward and time consuming and damaging...I heat gunned every 3-5 inches and had to pry the plastic back like 90*....there has to be a better way..

My way was oven for 12 minutes at 225, pull apart what I could while it cooled down and repeat. First headlight took around 3 cycles and second took 2 after I was comfortable with the amount of force to use.

[B6A4Dave]

So you just pulled the clear housing off?

I wasnt that smart...and feel like mine got fawked

[Kwarner]

Used a flat head to pry the channel up starting along the bottom and worked my way around. I went from the middle bottom round the side to the middle top which allowed me to just pull them apart.

[B6A4Dave]

Sounds like what I did with a different heating method....I just felt like I was destroying my headlights :P

[Hammie]

I felt like that too, but it has held together fine with silicone I used to seal it.. So it'll be the heat gun method again for me. The oven way is just too much time waiting,, while my headlight is baking in an oven no less! lol

[diagnosticator]

I pulled apart a damaged housing just to see what it takes. I doubt I could do it on housings I want to use without ruining them.

[diagnosticator]

I used a dremel tool with a diamond cutting wheel around the seam first, then a heat gun to soften the sealant, but it was still difficult and I made a mess of the job anyway. I don't understand how anyone does this without wrecking the housings.

[B6A4Dave]

Te heatgun method is definitely time consuming, the first one took about 2 hrs, then the second one I flew through in maybe 30 minutes...too scared the first time to F**K mine up hah.

[boy412]

I used a dremel tool with a diamond cutting wheel around the seam first, then a heat gun to soften the sealant, but it was still difficult and I made a mess of the job anyway. I don't understand how anyone does this without wrecking the housings.

Right with you on that one John...

[Kwarner]

I used a dremel tool with a diamond cutting wheel around the seam first, then a heat gun to soften the sealant, but it was still difficult and I made a mess of the job anyway. I don't understand how anyone does this without wrecking the housings.

You have to find that sweet spot of the right amount of pressure to use and exactly how far to push in the tool you're using to pry.

[n7plus1]

i did mine and you can hardly tell. you need to put them in the oven for more than 200degrees. more like 275...for 20 minutes and they come apart pretty easy.

i tried the heat gun as many people said its better...its way worse, dont even try it.

[n7plus1]

i did mine and you can hardly tell. you need to put them in the oven for more than 200degrees. more like 275...for 20 minutes and they come apart pretty easy.

i tried the heat gun as many people said its better...its way worse, dont even try it.

[Hammie]

Nate just curious what did you start with there? S4 or chrome e-codes?

and, they came apart after one round of baking at 275?

i did mine and you can hardly tell. you need to put them in the oven for more than 200degrees. more like 275...for 20 minutes and they come apart pretty easy.

i tried the heat gun as many people said its better...its way worse, dont even try it.

[Kwarner]

Even if you can't get them fully apart, just put them back in for a little while again. I agree that the oven is WAY easier than the heat gun method.

[glenngac]

yeah,i agree.

[Meighty7]

Gonna do this really soon now, just bought my b6 and was wondering how hard it would be

[B6A4Dave]

Even if you can't get them fully apart, just put them back in for a little while again. I agree that the oven is WAY easier than the heat gun method.

havent tried it on mine...but anything has to be easier than a heat gun

[diagnosticator]

i did mine and you can hardly tell. you need to put them in the oven for more than 200degrees. more like 275...for 20 minutes and they come apart pretty easy.

i tried the heat gun as many people said its better...its way worse, dont even try it.

I tried the oven method too, the housings started to melt and deformed when I pulled on the parts to seperate, but the sealant did not soften enough to release.

[agart]

I've done this on 3 sets of headlights so far, 1 set not being from an Audi but requiring the same steps. I've used a heat gun on all 3 and found that the key is patience. On the low setting(500*F) I kept going around the headlight for at least 20 min or so before I even attempted to start prying. You have to get the sealant soft all around before the lens will begin to break free. At that point start at one end and heat 4-5 inch sections as you go down and slowly pry. I found it is also easier to break apart the end closer to the high beam first and work towards the turn signal. I have yet to use an oven but I would imagine that keeping it at a temp around 200*F like others have mentioned for 10-15 minutes would be a great way to do the initial softening. Repeat for 3-4 min a few times as you work your way down the break.

[Hammie]

I tried the oven method too, the housings started to melt and deformed when I pulled on the parts to seperate, but the sealant did not soften enough to release.

Yea, exactly what I fear.. Melting everything but the sealant lol

[n7plus1]

nothing melted on me at all, shit was hot. i just used silicone hot pads for cooking to grip and pull and to guard myself from teh heat. they didnt come completely apart the first time but they did after the second attempt for a shorter amount of time.