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fly300kts
08-15-2009, 10:59 PM
Hi Guys,

Because a lot of questions have been asked on the subject numerous times, I took time today, to take some shots while I was doing a LED strip integration. Of course, this is not the only way to proceed, but it is my way, and it’s a safe way (you don’t end up with broken tabs or other issue). This DIY is performed on a Xenon housing (more complex than Halogen) but the same steps can be performed for both type of headlights.

This DIY has 2 chapters due to the number of pictures (too many - Right not granted by Admin)

Time = 1hr per headlight
Difficulty = 4

The Tools

WARNING: The internal chrome components are really fragile and I highly recommend wearing cotton gloves once you start to manipulate them.

Heat Gun
Some of you prefer to stick the headlight in the stove. To have personally gutted out numerous Xenon headlights and seen the amount of tinny plastic components, I don’t want to take the risk.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P1Large.jpg

Flat screwdriver
T25 Torks screwdriver (grinded to the diameter minimum, you will understand later why)

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P2Large.jpg

Using the flat screwdriver, snap off the clips: 5 of them

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P3Large.jpg

Pull off the rubber protector

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P4Large.jpg

Install the headlight on a soft rag (prevent scratching the lens) and you are going to heat up the seal between the housing and the lens. No need to heat the entire perimeter, the glue used is messy enough when soft and you don’t want it to stick to the chrome. Heat the area for 10 mn.

Materialized in red the area to be heated.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P5Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P6Large.jpg

Now, grab two rags, hold the headlight vertically and separate the lens from the housing. The lens shape on the turn signal side provides a good grip. If it’s too hard to pull, you can heat up a bit more the area.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P7Large.jpg

Use a razor blade to cut the cold sealant.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P8Large.jpg

Voila, headlight is open

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P9Large.jpg

Now you need to remove the internal housing. There are 3 screws holding it in place. Location materialized in red

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P10Large.jpg

Close up of screw #1

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P11Large.jpg

Close up of screw #2

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P12Large.jpg

Close up of screw #3

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P13Large.jpg

Now, the housing should slide off

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P14Large.jpg

On some headlights, it’s a bit more difficult because the housing stays clipped in the turn signal area. Gently pry under the plastic tab to release it.
Here is a close up of the tab that may stay clipped

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P15Large.jpg

Once the housing is removed, there is an additional screw to be removed right under the turn signal.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P16Large.jpg

At this stage, I have seen people banging the orange corner with the screwdriver: 99% of the time, you will end up breaking the turn signal tabs !!!


Now, the tricky screw: He is hiding behind the chrome housing. This is where I use my trimmed screwdriver and work it thru between the headlight housing and the chrome piece. Even if you scratch a bit the edge of the chrome housing, do not worry about it, you won’t longer see it once the headlight is reassembled.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P17Large.jpg

You can really see the sucker hiding on this one

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P18Large.jpg

Now, you are going to separate the two plastic parts of the turn signal.
Take a close look at the little plastic shaft preventing the separation

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P19Large.jpg

Using a razor blade, you are going to trim just a bit of the edge of the center pin, trying to make a chamfer.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P20Large.jpg

Once trimmed, it should look like this

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P21Large.jpg

And now, if trimmed enough, you will be able to slide and separate the 2 pieces.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P22Large.jpg

And Voila

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P23Large.jpg

Now, to remove the orange cap, just push on it, towards the inside.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P24Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P25Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P26Large.jpg

fly300kts
08-15-2009, 11:00 PM
Because most of you will use the opportunity to black out your headlight since they are open, I going to push a bit more the DIY and show you how to remove the chrome pieces off the internal housing.

Start by the biggest housing. From the inside, just gently pry with a flat screwdriver, the 4 surrounding clips and the chrome piece will release.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P27Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P28Large.jpg

Same process for the small chrome piece, pry on the small 4 tabs. You will have to apply more pressure on these because they are kept locked by a piece of plastic

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P29Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P30Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P31Large.jpg

To remove the last piece, using small pliers, bent a bit towards the center, the 2 bottom tabs and you will be able to slide the last piece out.

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P32Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P33Large.jpg

Now the housing is chrome free and you can spray the black

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P34Large.jpg

Time to put everything back together. First the central chrome piece

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P35Large.jpg

Then for the external one, start by the 2 top tabs and then drive in the 2 bottoms one using the flat screwdriver

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P36Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P37Large.jpg

When you reinstall the central one, make sure that these tabs

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P38Large.jpg

Lock into these

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P39Large.jpg

Reinstall the rear turn signal reflector with the top screw

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P40Large.jpg

Then snap back in place the top housing and secure both with the bottom screw

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P41Large.jpg

Reinstall now the internal main housing and secure with the 3 screws
Reinstall the lens
Grab a beer

You are done

I am around if any question

Phil

Doctor
08-16-2009, 02:56 AM
Excellent.
Having done it in the past using a different DIY, I wish I had this one instead.

I think it would be good, having some photoz showing, or explaining how the glass goes back in, as to whether it needs extra silicone or not. I hadnt put any, I used the OEM glue, some do.

Once again, excellent man. [:)]

jriddle11
08-16-2009, 04:01 AM
You are the man! Know if I just had the guts to do it myself.

fly300kts
08-16-2009, 04:16 AM
You are the man! Know if I just had the guts to do it myself.

[:D]
If still too scare, send them to me [up]

fly300kts
08-16-2009, 04:20 AM
Phil

AvanTTix
08-16-2009, 10:10 AM
To the Admins,

I was not able to post this DIY in one single post due to the amount of pictures.
I would be great if you could merge the PART 1 & Part 2 of this DIY.

Thank you

PhilAs you found out there is a limitation in the number of pics one can insert in one post, however there is no limitation as to the number of posts one can post in one thread... So when you've got too pics, just split them over multiple posts, i.e. reply to your thread... [;)]

Great DIY BTW! [up]

fly300kts
08-16-2009, 10:18 AM
^^ Thank you [up]

JasonR
08-16-2009, 10:45 AM
Great writeup! I did the clear corners on my old B7 using the screwdriver & brute force method, and this looks like a much more elegant solution... not to mention safer.

dubless
08-16-2009, 11:09 AM
Great write-up . One of the best diy's I've seen on here in a while! If I can't find a fairly inexpensive set up of euro-lights in the next few mos I may end up doin this mod.

fly300kts
08-16-2009, 08:24 PM
^^ Sorry, I had a set and I just sold it. I'll let you know if I get another one

Phil

jriddle11
08-16-2009, 08:32 PM
[:D]
If still too scare, send them to me [up]

I want to because I want the LED's too, but our new baby uses diapers up like they are free. [:D]

I just noticed I typed KNOW instead of NOW, boy I need to stop coming to this site when I am tired.

MMMB00ST_A4
08-16-2009, 08:39 PM
What is your paypal OP, so that i may send all my money to you??!! You are thorough! And hairy lol...thx for a killer write up

fly300kts
08-16-2009, 08:47 PM
^^ I am anal on everything I do [:D][:D]
I'm hairy because I am old [=(]

MMMB00ST_A4
08-16-2009, 08:54 PM
^^ I am anal on everything I do [:D][:D]
I'm hairy because I am old [=(]

lol, are/were you a pilot?

fly300kts
08-16-2009, 08:57 PM
^^ yes, thanks God, I am still a Pilot.... Did not lost my Medical......yet
In case you are interested: www.tbm850.com [hail]

MMMB00ST_A4
08-16-2009, 09:03 PM
^^ yes, thanks God, I am still a Pilot.... Did not lost my Medical......yet
In case you are interested: www.tbm850.com [hail]

Good to hear! Job security in this economy is the most reassuring thing anyone can ask for at the moment. I am extremely happy that the only way i could lose my job is if i screwed myself over [:D(which i dont plan on doing)

fly300kts
08-17-2009, 04:52 AM
^^ 10/4

fly300kts
08-17-2009, 08:29 AM
Great writeup! I did the clear corners on my old B7 using the screwdriver & brute force method, and this looks like a much more elegant solution... not to mention safer.

Glad you mention that, it reinforce my therory [up]

dblock110
08-17-2009, 08:53 AM
thanks great write up. i will def do next time my bumper is off

Phantom08
08-17-2009, 08:57 AM
awesome write up! Wish I had this when I was doing mine....then I wouldn't have used a screwdriver and partially scratch my housing. Plus now I know how to remove the trim so I can go back in a paint everything black. Thanks again.

07DPrellA4
09-22-2009, 07:44 PM
Where do you get the clear caps. I heard that you get them off some ecodes. Does it matter which model they are (i.e. B6,B5)? Thanks for any help.


Nevermind. Just found it. I'm retarded. Great writeup, will definitely use this when doing the mod soon.

nnnick
09-22-2009, 07:59 PM
+1 rep for you - great write-up!

Much more harder than just knocking it out with force though, haha.

fly300kts
09-23-2009, 04:54 AM
+1 rep for you - great write-up!

Much more harder than just knocking it out with force though, haha.

Thank you Nick, but more safe and it's the most important for me when I work on Customers Healights [up]

Phil

felondnb
09-23-2009, 07:20 AM
That's a great write up/DIY - I've still got my amber-cornered original headlights laying about, so I think I'll be doing some surgery & blacking out the casing while I'm there...

plus one for ur reputation [up]

rowyourown
05-07-2010, 02:55 PM
where can i get the clear caps

fly300kts
05-07-2010, 03:33 PM
where can i get the clear caps

They are as rare as finding a kidney !!

phil

Great White
05-07-2010, 03:37 PM
wow, that was very well done. congrats.

rowyourown
05-07-2010, 06:04 PM
haha well I've got two kidneys... trade for some clear caps?

pnoyworx
06-17-2010, 03:45 PM
I'm trying to CC my B6 Headlights. Heat gun more than 10mins, and still won't budge. Any tips? Thinking of throwing them in the oven, do I need to remove all the electronics/motor? Thanks

fly300kts
08-28-2011, 03:30 PM
I'm trying to CC my B6 Headlights. Heat gun more than 10mins, and still won't budge. Any tips? Thinking of throwing them in the oven, do I need to remove all the electronics/motor? Thanks

This DIY does not work on the B6 since the headlights are glued and not sealed like the B7

Phil

pnoyworx
08-28-2011, 10:57 PM
Thanks Phil... I figured it out after much effort. :)



This DIY does not work on the B6 since the headlights are glued and not sealed like the B7

Phil

kurupt_hawaiian
08-19-2012, 03:36 PM
Bringing this back from the dead... I've done clear corner twice before, but having a hard time with breaking the seal on these other headlights... its like they're sealed with something else. Heat does not melt the silicone to get it loose...if its even silicone. Any info? It is OEM bixenons.

mcpcartier
09-02-2012, 09:50 AM
Someone pm'd me asking which pieces I painted black and what paint I used so i figured I just add it to the tail end of this thread. I know I posted it somewhere else way back when but not sure where.

I followed phil's instructions and everything went exactly as he described. I painted two pieces black...

http://img140.imageshack.us/img140/3032/cimg0047a.jpg
By mcpcartier (http://profile.imageshack.us/user/mcpcartier) at 2012-09-02

I used dupli-color black trim paint...recommended by adub

http://img823.imageshack.us/img823/9043/p1230081.jpg
By mcpcartier (http://profile.imageshack.us/user/mcpcartier) at 2012-09-02

Finished look without bumper installed...

http://img594.imageshack.us/img594/4779/cimg0054w.jpg
By mcpcartier (http://profile.imageshack.us/user/mcpcartier) at 2012-09-02

Before and after....

http://img59.imageshack.us/img59/1189/headlightsbeforeafter.jpg
By mcpcartier (http://profile.imageshack.us/user/mcpcartier) at 2012-09-02

fly300kts
09-09-2012, 05:02 AM
Great job. By the way, wheels removal is not required

Phil

mcpcartier
09-14-2012, 06:08 PM
^^^^ Thanks Phil,

I really appreciate all the info you've posted on AZ, I'm referring to it all the time (TB change, vacuum pump, clear corners, control arms come to mind right away...I'm sure I've used much much more).

Yeah, wheel removal is not required. Can't recall why I took them off, probably had a reason at the time.

fly300kts
09-22-2012, 05:24 AM
^^^^ Thanks Phil,

I really appreciate all the info you've posted on AZ, I'm referring to it all the time (TB change, vacuum pump, clear corners, control arms come to mind right away...I'm sure I've used much much more).

Yeah, wheel removal is not required. Can't recall why I took them off, probably had a reason at the time.

Your welcome

DDamian1
09-30-2012, 12:13 AM
Awesome DIY and thx fo rthe lenses Phil but i got a prob. one of my lenses are glued with a different epoxy or something. it s like rubber and when i heat it up it doesn't let go. the plastic around burns faster then the glue inside. there is no way i can open it. any ideas on how i can get get inside?

fly300kts
10-07-2012, 06:29 AM
Awesome DIY and thx fo rthe lenses Phil but i got a prob. one of my lenses are glued with a different epoxy or something. it s like rubber and when i heat it up it doesn't let go. the plastic around burns faster then the glue inside. there is no way i can open it. any ideas on how i can get get inside?

The production date of this headlight is propably post 2011. Not sure why but Audi has changed the sealant and this one is a real PITA, similar to B6 model
It can be done by carefully scrapping the sealant. You are in for a long ride

Phil

DDamian1
10-07-2012, 11:26 AM
for a min i though i had my old headlight, when i got the car the right lens was jumping up and down, once i got to my dealer they were happy to replace it do to the projector had too much internal "damage". once i hit the silicone doing the cc mod i thought it was fixed not replaced. the glue got me off track. thx for the info i never though of this possibility.

20AE428
10-26-2012, 07:41 PM
Planning on getting to this mod this week but before I go splitting my lense open I hope this doesn't sound dumb. If you remove the orange lense do you not have to replace the bulb with an amber bulb? If so what bulb model #?

B7Joe
02-20-2013, 06:42 PM
Cc'd my bixenons today. I was sweatin' but it worked out in the end. When trying to assemble one of the corner reflectors, it slipped out of my hands and bounced on the concrete. Amazingly nothing happened to it. I strongly recommend wearing gloves and changing them right away if you get even a tiny spot of adhesive on them. That chrome finish is extremely delicate and unforgiving.

When I did my old halogens I just left the bare corner reflector, sans amber. Did it right this time. Replaced with clear lenses and installed OEM euro chrome bulbs. Looks amazing. I highly recommend this mod if you have the nerve!

fly300kts
02-22-2013, 12:19 PM
Planning on getting to this mod this week but before I go splitting my lense open I hope this doesn't sound dumb. If you remove the orange lense do you not have to replace the bulb with an amber bulb? If so what bulb model #?

http://www.audizine.com/forum/showthread.php/295141-Sharing-Experience?highlight=sharing

Phil

Noodle
05-21-2013, 06:58 PM
I'll start by saying this was NOT as hard as I was making it out to be. Time consuming, maybe, but not hard at all. Much easier than on my old B6. That being said, read below.


Same process for the small chrome piece, pry on the small 4 tabs. You will have to apply more pressure on these because they are kept locked by a piece of plastic

http://i31.photobucket.com/albums/c395/fly300kts/CC%20DIY/P29Large.jpg

I did this step with my first headlight (pushing in the tabs on the smaller chrome piece) and ended up breaking one. Too much man I guess.

Anyway, it might save some people a broken tab or two by doing the top part first. I took a pic when I got to it (but after I removed the piece I'm talking about unfortunately) and it went much smoother.

I circled the pieces in red that you can push in and pull the top piece off with plyers/fingers/tool of choice.
http://two4one9.com/pics/car/IMG_0326.jpg

Hopefully it makes it easier for everyone.

Huge thanks to Phil for the write up. He even offered me the clear lenses but I'm too impatient [wrench].

Sorry for the fuzzy pic. Still getting used to the DSLR, but you'll see what I mean when you come to it.

Der König
06-11-2013, 11:50 AM
when reinstalling the lense is everyone just putting the 5 metal clips back in place to hold it snugly then heating the parameter?

Thanks for the write up Phil, on my last step of reinstalling the lense and used your cleaner corner caps, fit great!

Schweini
06-11-2013, 12:39 PM
when reinstalling the lense is everyone just putting the 5 metal clips back in place to hold it snugly then heating the parameter?

Thanks for the write up Phil, on my last step of reinstalling the lense and used your cleaner corner caps, fit great!

I bought silicon and re-applied around the perimeter before putting the lense back on.

Been 2 years roughly and no issues

Der König
06-11-2013, 01:48 PM
Ok, I worked the lense with a heat gun until in position to install the metal retaining clips. After that I heated the perimeter for a while, seemed to work but will report back if any issues. All done!

scottyyBb7
06-18-2013, 06:43 AM
was there any moisture that got in there? really wana do this but kinda nervous, thinking about buying a pair of headlights to test with, did you have to take the bumper off

Schweini
06-18-2013, 08:53 PM
was there any moisture that got in there? really wana do this but kinda nervous, thinking about buying a pair of headlights to test with, did you have to take the bumper off

no moisture at all, make sure you re-seal with a generous amount of silicon. Yes, bumper has to come off

wflan
07-04-2013, 12:46 PM
I did a more custom paint job and installed LED strips while I was CCing mine (:
Close

http://www.audizine.com/gallery/data/543/medium/IMAG2040.jpg

Mid

http://www.audizine.com/gallery/data/500/medium/IMAG2038.jpg

Mid

http://www.audizine.com/gallery/data/500/medium/IMAG2039.jpg

Far

http://www.audizine.com/gallery/data/543/977688_10200500297204634_826067675_o_copy.jpg

mscottdemarco
11-10-2013, 09:58 PM
^^ I am anal on everything I do [:D][:D]
I'm hairy because I am old [=(]

Thank you for being anal. I just used your DIY and the paint is drying now. Im pretty sure I just bought the CC lenses from you too. Jeez that screw in the corner is a bugger. Thanks for your DIY and what you have done for the community.

fly300kts
11-26-2013, 07:05 PM
Thank you for being anal. I just used your DIY and the paint is drying now. Im pretty sure I just bought the CC lenses from you too. Jeez that screw in the corner is a bugger. Thanks for your DIY and what you have done for the community.

Thank you for the kind words

Phil

Zathrax
12-07-2013, 05:56 PM
Anyone know if plastidip is suitable for this? (anyone tryed?) thinking long therm effect?

- M

xander3zero
01-03-2014, 03:26 PM
Gonna be doing this mod pretty soon, anyone know how long the existing headlight sealant takes to dry? Any tips to a moisture free re-sealing? I am going to try to reuse the existing sealant but if I end up needing more what specifically should I look for at an auto store?? Thanks

Sent from my Nexus 7 using Tapatalk 4

fly300kts
01-16-2014, 05:12 PM
Anyone know if plastidip is suitable for this? (anyone tryed?) thinking long therm effect?

- M

Gets too hot inside the headlight during summer

Phil

fly300kts
01-16-2014, 05:13 PM
Gonna be doing this mod pretty soon, anyone know how long the existing headlight sealant takes to dry? Any tips to a moisture free re-sealing? I am going to try to reuse the existing sealant but if I end up needing more what specifically should I look for at an auto store?? Thanks

Sent from my Nexus 7 using Tapatalk 4

Most of the people reheat the sealant prior closing the headlights and it does the trick

Phil

SkillzVrt
01-20-2014, 09:20 PM
Only person making the lenses is Phil. I want to order them since my bumper is getting repainted this weekend but saw it takes 5 days to make and then ship out. Can't wait to do this

fly300kts
01-29-2014, 05:14 PM
Only person making the lenses is Phil. I want to order them since my bumper is getting repainted this weekend but saw it takes 5 days to make and then ship out. Can't wait to do this

You are set

Phil

bcaudi
02-01-2014, 05:27 PM
1) thanks for the DIY, this helped a TON!
2) I'm not sure if Audi changed the screws, but on my Bi-Xenons, they were all T20 instead of T25. Anyone else run into this?

makaheehee
03-06-2014, 08:35 PM
Its hard to tell... But does anyone have pictures of Clear Corners vs just taking out the amber cap? How would it look without a cap?
Thanks

fly300kts
03-08-2014, 04:42 AM
Its hard to tell... But does anyone have pictures of Clear Corners vs just taking out the amber cap? How would it look without a cap?
Thanks

Not good because the gap makes the area like unfinished

http://www.audizine.com/gallery/data/500/medium/IMAG2038.jpg

Phil

West.point1
04-08-2014, 11:50 AM
Phil I noticed your eBay doesn't have any clear caps up anymore, do you have any available. If not do you know where I could find some?

bcain93
04-25-2014, 11:52 AM
Just a quick question that I might have missed. I know the heat gun heats up the seal on the housing, when you reinstall it, what do you have to do to completely seal the housing back so it does not leak? Thanks.

247ride
04-26-2014, 12:05 PM
Just a quick question that I might have missed. I know the heat gun heats up the seal on the housing, when you reinstall it, what do you have to do to completely seal the housing back so it does not leak? Thanks.
I did the mod yesterday. I used silicone sealant.

MarcusDubya77
05-09-2014, 10:02 AM
Great write up. On my short list of things to do!

Stanced_Audi13
05-09-2014, 03:23 PM
Phil I noticed your eBay doesn't have any clear caps up anymore, do you have any available. If not do you know where I could find some?

Bump, wondering this as well

Sent From The Drivers Seat Of My Slammed B7 A4

B5SilverS4
05-10-2014, 11:21 AM
Great DIY Phil, thank you for sharing!

fly300kts
05-25-2014, 09:14 PM
Great DIY Phil, thank you for sharing!

Your welcome

Phil