Okay, so I finally got some time to write this up and upload my pics. After putting the headlights back on, I couldn’t be any happier with the results! This was my 2nd time doing something like this and so everything was very straight forward. Anyway, for a very detailed write up on getting the headlights out, check out this write up…VERY detailed!
http://www.rs6.com/forum/showthread....&threadid=3862
You’ll need the following tools/materials:
- T-20 & T-25 drill bit
- Drill bit holder/extender
- Old T-shirt
- Duplicolor hi-heat black engine enamel
- 400 grit wet sand paper
- Saran Wrap
- Masking tape
- Elmer’s Black silicone
- Flat head screw driver
- Latex gloves
- Time
- Patience
On with the pics and my comments!!!!
Use a Torx-25 bit to remove bolts 1 and 2. For the 3rd bolt, take a flashlight and look into that hole. You’ll see the bolt sitting there just mocking you. =D Unless you take the bumper off (which I did not), it is utterly impossible to get to that bolt. I went to ACE hardware and purchased a bit holder/extender for $14. Well worth it!
Once the bolts are off, you’ll see on the other write-up that he’s talking about a black cylinder that you need to detach from. Here is a picture of what he’s talking about.
Here is the bit holder/extender I bought at ACE.
It is crucial to use any kind of soft cloth when removing the headlights otherwise you WILL scratch the bumper.
This is where the release latch is to remove the wiring harness from the headlight assembly.
Here’s one…
And two…
For this next part, have COMPLETE faith in yourself and don’t let the oven scare you, it WON’T damage your headlight components. What I’ve found to be helpful is to get a used t-shirt and soak it in warm water. Wrap the headlight inside of the wet t-shirt and place it on the tray (which should be on the lowest hook). Pre-heat to 220 and BAKE it for 5-6 minutes and then pull it out with oven mittens! Get a flathead and Start on the bottom and pry that sucker open…when you have enough clearance to sink your claws in, rip the clear housing completely away from the black housing.
Using 400 grade wet sand paper, sand the chrome plastic housing once you get it out of the clear housing. They should turn out white. I didn’t see the point of taking the chrome pieces out of the headlight unit so I left it in and taped everything off. I actually used saran wrap and laid it across the turn signal area, projector lens, and the high beam area. Just fit the saran wrap around and use masking tape to tape it off. The post earlier with the white A6 had his headlights COMPLETELY blacked out. I wanted a little contrast so I taped off the circle ring around the projector lens. Here are a few pics of the taping of the housing…took a bit of time, but SOOO worth it for the look.
I used the Duplicolor Low gloss Engine Enamel paint from Schuck’s to paint. Lay the pieces down and using a back and forth pattern, lightly spray every part of the exposed parts. Do NOT hold the can of paint in one location. Constantly use the back and forth motion. If one spot doesn’t look painted as much as another part, don’t go back and try to fill it in. Get it on your next coat. This stuff dries pretty quickly so apply 5 coats. The entire painting process took about an hour. I let the paint cure and completely dry for a few hours while I went out to grab a burger at Red Robins with my girlfriend and a friend. Once the paint is all dried and looks even, start putting the plastic pieces back in their respective clear housings.
CAREFULLY remove the saran wrap and tape from the back unit assembly. I used a sharpie to clean up any small spots that may have chipped off while removing the tape/saran wrap because I’m very picky about those kinds of things. =P
Take the bottle of silicon and put that in the oven for 3-4 minutes at 210 (temp). Take it out, put it in the caulking gun and outline the groove on the back unit piece with the silicon. Don’t be afraid to use a lot since this is ALL the silicon will be used for…but not so much to the point where the entire housing will be filled with globs of silicon. =D
Press the two pieces back together and immediately grab those clips to keep the headlight assembly well pressed. Once that’s on, wrap the headlights in the damp tshirt and let it bake for about 2 or 3 minutes, take them out and press them together flush! Take the silicon again and go to town on the outside edge where the two pieces meet. Use your finger (with latex glove on of course) and smooth out the silicon making sure that EVERY crevice is sealed. Take some time here and make sure you get everything perfect…otherwise you’ll have to do this all over again later.
Once it’s set, place them where NOBODY will mess with them and let them cure for a full 24 hours.
Congrats!!!! You did it!!!
Here is the finished product…along with a few other photos of my LED tails and my custom magnaflow exhaust setup.
ENJOY!
Originally Posted by oc-drop
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