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HOW TO: Bake Open Stock Headlights
This gets asked at least three times a week it seems. Here's a quick and relatively painless how-to.
I use, and recommend an electric oven. My instructions are specifically for an electric oven. People have done it in a gas oven, but I don't recommend it.
Oven @ 250° F. One lamp at a time, on a cookie sheet, lens facing up, all bulbs and gaskets removed.
15 minutes in the oven at this temp
(wear some sort of gloves to do this, lamp will be HOT) pull lamp and pry around the inner corner where the turn signal bulb goes with a small pry bar or butter knife. Keep working this corner until you can get a finger or two in between the lens and body. Once you can, use your hands to firmly, yet slowly and gently pull the lens from the body.
If you can't get it apart within about 3-4 minutes, then place back into oven for 5 more minutes then repeat the above step until it pops apart.
I (and most retro-fitters) recommend "Nissan sealant" to re-assemble the lamps with (Part # B6553 - 89915)
Two options here. 1) heat up the housings again to soften the OEM sealant, then lay a bead of the butyl tape (Nissan sealant), and smoosh the lens back on, or, 2) remove all the OEM sealant with a dremel or an X-acto, lay a bead of the butyl tape, then hit it with a hair dryer on the hottest setting (no heat gun, too hot) until it's nice and soft, then smash the lens back on with all your might.
*** If you're using Depo/eBay lamps, then you may not need any extra sealant to re-seal, as long as you're really careful when opening them up in the first place. ***
Voilą! That's all there is to it folks. Not nearly as hard as it seems. Hope this helps!
Last edited by wiggy; 05-23-2010 at 08:09 AM.