I am curious to learn if anyone has successfully opened and reassembled a headlight assembly. If so, what was the procedure used and the level of success. I recently watched a YouTube fast forward demo of a Russian guy opening up a xfire light assembly. It was difficult to see or follow any of the difficulties involved with doing this. They used a combination of cutoff wheels and heat to separate the reflector half from the lens. My main reason for doing this is to clean the inside surface of the lens. Before attempting to separate the assembly I will try the solvent coated pad and magnet technique. Accessibility is the only constraint when using this technique.

 

This has been done many ties, Accessibility is not a problem, I highly advise doing this with the unit removed from the car.
By "solvent" , I hope you are referring to ethanol or 95% iso.
DO NOT, I repeat DO NOT use acetone unless you desire a nice warm glow from your headlights.

 

I believe that is Methanol George

 

Slightly different question. How have people cleaned the projector lenses? Not the clear outer cover, the lenses themselves? I can plainly see from the outside of the car that there is a coating from condensation and dust inside the lenses, and that coating is attenuating the light output, even though my outer covers are clear.

 

Yes, methanol - senior moment.

 

ala_xfire
I am assuming the headlight lens is Lexan (polycarbonate) which I know like most clear molded polymer materials is not compatible with acetone. It will attack and dissolve it. Where can I get a small amount of ethanol? Is dry gas 100% ethanol or are there additives which will leave residuals? Thanks

 

2 methods :
1. remove the unit, pour 3 oz or so of methanol thru the little brow light hole, swish around and empty. repeat. dry with moisture free compressed air.
2. find a small magnet that will fit thru the hole, wrap microfiber around it and secure with hot glue gun.
Soak it with methanol and move it around the inside lens with a second magnet wrapped in dry microfiber.

I used method 1 years ago and they are still clean.

 

Not sure how the #2 method would work on the glass portions of the lenses. For the outer cover plastic, yes, but I am talking about the actual projector.

 

I was told to not worry about the lens, cloudy is normal. Who knows .....

 

Yeah, it's cutting down the light. I'll figure something out. Have an idea or two.