Here is a simple wood jig I made for mounting a headlight in my vise for polishing .
holes are 3/4 inch and 12 1/4 inches apart :

 

Nice. What did you do to yours?

 

That's one of the ones that RedDog sent me.
Now I have one GOOD and one not so good PS ( right ) headlight units.
The DS that Bob sent is totally toast with a shattered lens.

 

Is that picture before or after you polished the lens?

 

After first pass. Still a lot to do before it really shines.

I did an initial 500 / 800 / 1000 / 3000 sanding and a polishing, then a waxing to see what I have.
Not good enough yet ......

 

What are the hex fasteners, are they OEM parts or?
I have never seen a unit out and in my hand.

 

Those are the OEM lower adjuster fittings.
Due to body/panel variations, these are designed to provide a tight fit to the lower body mounting tabs.
Here's the process :
When re-installing the unit, get it in place with the eyebrow light inserted, screw these adjusters in just so they are started properly,
secure the upper two bolts, then screw the adjusters in until they just contact the body mounting tab.
Now insert and tighten the lower 2 bolts.

 

Thanks, now we know.

 

Historical moment !
The Padawan instructs the Master .......

 

How hard is it to get the headlights out?

 

Not a walk in the park, but doable :
The headlight removal process depends on if you have a CAI or not.
With a CAI, you can easily access the lower center 10mm bolts ( after removing the grille ), without CAI you will need a socket on a long extension and a flashlight to go up through the fog light doors.
The lower outer 10MM bolts can be removed up through the little door as well, but many have found it easier to remove the side running lights and access through the fender.

1. remove the 4 bottom bolts.
2. remove the 4 top bolts.
3. rotate the assemblies so you can remove the eyebrow lights and disconnect the wiring harness.
4. remove the lower threaded spacers.
5. remove the units ( a bit of wiggling is required, but if you hold your tongue just right, you can do it. )

 

That's really a simple mounting jig for this headlight cleaning. Allows one to not be worried about contacting the painted body surface if an aggressive cleaning/polishing is needed.

THX