Last weekend I removed my headlights from my car.
Finally, this weekend I was able to get some time to get them opened.
all in all, it took about twenty minutes to do.
I was able to do this without the use of the oven, I left all parts in place including the bulbs
I took my time removing the rings.
Steps I took are:

- look to see where the double sided adhesive tape was applied to hold th rings in place.

- Since the tape was on the lower half of the rings, I found two tabs on the sides, I began with the smaller of the two tabs and worked my way down slowly lifting to unfasten the tape.
Once the tape is taken care of, you can finish removing the ring by carefully popping the rest of the clips. (It has been stated, and indeed this is the trickiest part of the whole project.)

- So having not used the oven method, and in the midst of holiday decorating. I ended up sitting in front of my fireplace with my headlights.
Kind of a different method, but it worked like a charm.
It was warm enough to soften up the glue.
I slowly worked my way around the headlight, carefully wedging the screwdriver under the lip while at the same time lifting the lens.

I had both lenses off within ten minutes.

This week I will be sanding the parts in order to paint them.

An alternate to the fireplace, that may work just as good is a space heater.
You really only need a few minutes to warm the plastic up. It's also a good method since you can monitor the temp and condition of the plastic.

Will post more later as well as pictures.

 

Yes, photos please!

So you put them on the fireplace hearth and just pried at them? Interesting technique and LOTS less scary that oven-baking (at least IMHO)... I've wanted to do this MOD for AGES and this might be a good way to quell my fears.

Can you talk about disconnecting the xenons and removing them as well? Did you unhook the negative battery terminal before monkeying with the connectors? I know xenons draw a LOT of juice...

 

My place has one of those gas fireplace in it.
I was sitting in front thinking " do I really want to put plastic in the oven...

So I just sat there instead, gradually rotating the headlight and feeling the surface till it was all evenly warm.
Once it was I was able to rather effortlessly open the headlights.
There is one spot you will notice that has a notch in it on the under site of the light, that is where I used the screwdriver.
I was able to get it just under the lip of the lens cover and carefully applied pressure while lifting with my other hand.
Similar to opening a paint can, once started I kept working my way around till it was all off.

I was amazed!
And I'm going to close them the same way.
Before doing anything I disconnected the battery.
There are three bolts you have to undo.
You will have to unscrew the lower light housing the metal box, in order to get to the two bolts.
Then I carefully aligned the headlight to lift out of the hood.
There is one plug you disconnect and then a clasp you pinch in order to remove the washer housing.

I will post some pics this evening.

 

Sweet! I have a gas fireplace as well - this is awesome, awesome news. I heard that the first version of the headlights turned yellow and warped in the oven, so I'd told myself that this was a MOD I would not do. However, now I'll have to re-assess that.

Does anyone know if they make a dark silver (like anthracite) in the Krylon? I'd like to not hassle with priming if I don't absolutely have to, but it's no huge deal if I do.

Thank you!!

 

Just get the OEM paint. Let me know if you find a nice Dark Silver color.

 

I looked for an anthracite paint for a while. I tried a few diffferent ones and nothing matched. Most were too green. I tried contacting MINI with no avail. My body shop said that they could try to match it. Long story short... Apparently MINI's anthracite paint doesn't exist. I think it is kept in area 51 with the aliens and the soundstage where they filmed the moon landing.

 

I've heard that this is a good type of paint for no hassle painting.

 

Well my car's purple so I don't need an exact color match - I'm just thinking that satin black, while nice, might not highlight the complex shapes of the xenon housings as well as something with a touch of metallic flake in it.

 

I ordered a OEM Jet Black paint from minspeed.net
When I ordered my Orciari Cowl Scoops.
They carry all mini colors available.
Good Luck

 

I'm going with Jet black on the rings, w/clear protective film to avoid damage.
On the inside I'm going with a black that has a slight silver flake to it.
Think it will be nice since it will be seen when the lights are on.

 

Can't wait to see those! Best of luck on the painting process.

 

Thanks ImagoX, Once I get there....you can be sure I will post some pictures.

 

Thanks for coming up with this method! What would you think of using a hair dryer? Also, just how warm do you have to make it -- i.e. not hot to the touch?

 

Correct, not hot to the touch.
A hair dryer might work, depending on how good it is.
You really only need to loosen it up, so it becomes pliable again.
I used the fireplace to keep my hands free in order to rotate the headlight and spread the heat evenly.

Either way you choose to get there, find the notch I mentioned on the underside of the light housing. carefully wedge a flat head screwdriver under enough so you are below the lip of the lens cover and lightly start to put pressure as you pull at the lens. Once it's warm enough it should begin to open....trust me you will know.
Don't force it at all though, the plastic CAN crack!
Good Luck!

 

Just a quick note from my "Joey Mod" adventure this past weekend, "Take Your Time" I got in a rush and now will have to take one apart again to fix a problem that was easily avoidable. Oh and all the stories I hear about how easy it is to remove the lenses all must defiantly be post facelift. 04's are a PITA!
Jason

 

Just out of curiosity...what did you have to go back in and fix?
I have an 05 just to let all know.
And do take your time, one could easily crack the plastic if they rush the job.

 

Well first I got in a hurry and was having trouble getting the lenses off. Bake, pry, bake , pry. Wound up deforming the crap out of the housing but did not crack the lens. Second I did not get all the old adhesive out. Again running out of time, so they do not sit as flush as before. And third, when I put the bulbs back in somehow the highbeam in one was crooked and pointing towards the housing. I turned all the lights on (and left them on for a minute) to make sure they worked. I noticed the crooked bulb and fixed it. Monday morning I go out and look and the paint where the highbeam was pointing is cracked and peeling.
All in all, everyone that has looked at my car can not see the problems, but none of them are as **** as me when it comes to cars. If you are going to do this just make sure you have the time. I have been wanting to do this since the day I got my car, and decided Saturday night that it was time. Just poor planning on my part.
Jason

 

Thanks for the feedback Jason and I'm sorry to hear your troubles.
The melting issues were exactly what I was afraid of.

I hope you were able to get in and clear up the cracking paint
I am taking my time to find the right paint, as well as sand and prime all parts.
What type of paint did you end up using...just curious.

 

I used the Fusion paint. I have used it on everything else and never had any problems. I don't think the paint was the issue, I'm sure it is all on me. Heck I'm using that paint under the hood and it is holding up fine under there!
I'm positive that it was an issue of the paint not being cured enough and the light sitting almost right on it.
Jason

Oh, and I did scuff up the parts with steel wool, and made sure everything was clean and dust free.
Good luck with your project and post pics when done. As for me, pics will come when I fell it's worth showing. lol

 

True...That's no good.
How long did you let it dry for, my concern is the dry time since it's 30 degrees here now.

 

Not long enough!
Probably about 20min between coats, 3 coats, and 20before install. Did I mention I was out of time!?! This is my daily driver. Oh and it was in the upper 60's low 70's this weekend but windy as hell. Got to love Texas winters!

 

Multiply your dry times by ten I guess for me....I'm here in jersey city...on the water no less. So here it's the opposite, windy as hell but in the 30's..
I think I am going to get a space heater or something to aid in the drying.

 

Good idea. Next time I'll rebake them as others suggested to help soften up the adhesive again and aide in getting the lens more flush. I also sealed everything back up with black silicone so even more fun for me re-opening.
Oh well, live and learn. It's just a car right? I know a few soldiers in Iraq who would love to have my "problems"
Jason

 

Put them near the fireplace again (just not as close). At least the air will be warm, dry, and will be flowing past the pieces as it drafts up the chimney.

 

Good call!
A possibility if my girlfriend isn't around.
She's a big fan of fresh paint....
I was thinking about that though, my fireplace is in a new condo, so it's a gas fireplace with glass over the front. No air passing anywhere.
I'll figure something out.