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  1. #1
    Veteran Member Four Rings fly300kts's Avatar
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    DIY: CC (Clear Corner) Mod

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    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.



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



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



    Pull off the rubber protector



    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.




    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.



    Use a razor blade to cut the cold sealant.



    Voila, headlight is open



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



    Close up of screw #1



    Close up of screw #2



    Close up of screw #3



    Now, the housing should slide off



    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



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



    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.



    You can really see the sucker hiding on this one



    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



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



    Once trimmed, it should look like this



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



    And Voila



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



    Last edited by AvanTTix; 08-16-2009 at 10:07 AM.

  2. #2
    Veteran Member Four Rings fly300kts's Avatar
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    CC Mod: The DIY - Part 2

    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.




    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





    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.




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



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



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




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



    Lock into these



    Reinstall the rear turn signal reflector with the top screw



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



    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

  3. #3
    Veteran Member Four Rings Doctor's Avatar
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    Re: CC Mod: The DIY - Part 2

    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.

  4. #4
    Veteran Member Four Rings jriddle11's Avatar
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    Re: CC Mod: The DIY - Part 2

    You are the man! Know if I just had the guts to do it myself.
    Audi Brand Specialist / Social Media Manager / Spokesperson Byers Imports (Audi, VW, Porsche, Subaru)

    Current: B7 OEM+ and C7 OEM
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  5. #5
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY - Part 2

    Quote Originally Posted by jriddle11 View Post
    You are the man! Know if I just had the guts to do it myself.

    If still too scare, send them to me

  6. #6
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY - Part 1

    Phil
    Last edited by fly300kts; 08-16-2009 at 10:17 AM.

  7. #7
    Established Member Four Rings AvanTTix's Avatar
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    Re: CC Mod: The DIY - Part 1

    Quote Originally Posted by fly300kts View Post
    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

    Phil
    As 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!
    Stéph - Moderator

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  8. #8
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY

    ^^ Thank you

  9. #9
    Senior Member Three Rings
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    Re: CC Mod: The DIY

    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.

  10. #10
    Veteran Member Three Rings dubless's Avatar
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    Re: CC Mod: The DIY

    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.
    DTM....FTW!!!!

  11. #11
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY

    ^^ Sorry, I had a set and I just sold it. I'll let you know if I get another one

    Phil

  12. #12
    Veteran Member Four Rings jriddle11's Avatar
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    Re: CC Mod: The DIY - Part 2

    Quote Originally Posted by fly300kts View Post

    If still too scare, send them to me
    I want to because I want the LED's too, but our new baby uses diapers up like they are free.

    I just noticed I typed KNOW instead of NOW, boy I need to stop coming to this site when I am tired.
    Audi Brand Specialist / Social Media Manager / Spokesperson Byers Imports (Audi, VW, Porsche, Subaru)

    Current: B7 OEM+ and C7 OEM
    Previous: B5, B6, B6 USP All OEM+

  13. #13
    Veteran Member Four Rings MMMB00ST_A4's Avatar
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    Re: CC Mod: The DIY

    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
    -Brandon

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  14. #14
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY

    ^^ I am anal on everything I do
    I'm hairy because I am old

  15. #15
    Veteran Member Four Rings MMMB00ST_A4's Avatar
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    Re: CC Mod: The DIY

    Quote Originally Posted by fly300kts View Post
    ^^ I am anal on everything I do
    I'm hairy because I am old
    lol, are/were you a pilot?
    -Brandon

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  16. #16
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY

    ^^ yes, thanks God, I am still a Pilot.... Did not lost my Medical......yet
    In case you are interested: www.tbm850.com

  17. #17
    Veteran Member Four Rings MMMB00ST_A4's Avatar
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    Re: CC Mod: The DIY

    Quote Originally Posted by fly300kts View Post
    ^^ yes, thanks God, I am still a Pilot.... Did not lost my Medical......yet
    In case you are interested: www.tbm850.com
    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)
    -Brandon

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  18. #18
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY

    ^^ 10/4

  19. #19
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY

    Quote Originally Posted by JasonR View Post
    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

  20. #20
    Veteran Member Four Rings dblock110's Avatar
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    Re: CC Mod: The DIY

    thanks great write up. i will def do next time my bumper is off

  21. #21
    Established Member Two Rings
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    Re: CC Mod: The DIY

    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.

  22. #22
    Registered Member One Ring
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    Re: CC Mod: The DIY

    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.
    Last edited by 07DPrellA4; 09-22-2009 at 08:14 PM.

  23. #23
    Veteran Member Four Rings nnnick's Avatar
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    Re: CC Mod: The DIY

    +1 rep for you - great write-up!

    Much more harder than just knocking it out with force though, haha.
    Current: 2012 Audi TT-RS | HREs, MSS Kits, oCarbon, and most of the 034 Catalog
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  24. #24
    Veteran Member Four Rings fly300kts's Avatar
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    Re: CC Mod: The DIY

    Quote Originally Posted by nnnick View Post
    +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

    Phil

  25. #25
    Veteran Member Three Rings felondnb's Avatar
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    Re: CC Mod: The DIY

    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
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  26. #26
    Senior Member Two Rings rowyourown's Avatar
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    where can i get the clear caps
    Eibach springs, Bilstein sport shocks, GIAC, 034 HFC, RS4 rear sway, V710s, Hankook Ventus V12 235/40/18

  27. #27
    Veteran Member Four Rings fly300kts's Avatar
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    Quote Originally Posted by rowyourown View Post
    where can i get the clear caps
    They are as rare as finding a kidney !!

    phil

  28. #28
    Veteran Member Four Rings Great White's Avatar
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    wow, that was very well done. congrats.
    Ibis White 2.0T Quattro, S-Line Ti Pkg. 6MT | Mods: 35% Tint |APR 93 | EVOMS Intake | Stasis Exhaust |Koni Coilovers | RS4 Sway Bar | 12mm Spacers | Hankook Ventus V12 Shoes | Brazilian Driver

  29. #29
    Senior Member Two Rings rowyourown's Avatar
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    haha well I've got two kidneys... trade for some clear caps?
    Eibach springs, Bilstein sport shocks, GIAC, 034 HFC, RS4 rear sway, V710s, Hankook Ventus V12 235/40/18

  30. #30
    Senior Member Three Rings pnoyworx's Avatar
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    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

  31. #31
    Veteran Member Four Rings fly300kts's Avatar
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    Quote Originally Posted by pnoyworx View Post
    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

  32. #32
    Senior Member Three Rings pnoyworx's Avatar
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    Thanks Phil... I figured it out after much effort. :)


    Quote Originally Posted by fly300kts View Post
    This DIY does not work on the B6 since the headlights are glued and not sealed like the B7

    Phil

  33. #33
    Veteran Member Four Rings kurupt_hawaiian's Avatar
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    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.
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  34. #34
    Veteran Member Four Rings mcpcartier's Avatar
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    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...


    By mcpcartier at 2012-09-02

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


    By mcpcartier at 2012-09-02

    Finished look without bumper installed...


    By mcpcartier at 2012-09-02

    Before and after....


    By mcpcartier at 2012-09-02
    2007 2.0T Q 6MT, S-Line, Ti Package, BB
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  35. #35
    Veteran Member Four Rings fly300kts's Avatar
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    Great job. By the way, wheels removal is not required

    Phil

  36. #36
    Veteran Member Four Rings mcpcartier's Avatar
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    ^^^^ 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.
    2007 2.0T Q 6MT, S-Line, Ti Package, BB
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  37. #37
    Veteran Member Four Rings fly300kts's Avatar
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    Quote Originally Posted by mcpcartier View Post
    ^^^^ 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

  38. #38
    Established Member Two Rings DDamian1's Avatar
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    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?

  39. #39
    Veteran Member Four Rings fly300kts's Avatar
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    Quote Originally Posted by DDamian1 View Post
    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

  40. #40
    Established Member Two Rings DDamian1's Avatar
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    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.

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