My damn covers for the headlight bulbs that screw on inside the engine bay are f'n melted & barely stay on. I tried the factory covers & they were too large. Anyone else have this problem & what did you do to fix 'em. Thanks.

are you using high wattage bulbs? aftermarket housings are usually less resilient to excessive heat. it's not that big a problem leaving the covers off though.

Im not trying to flame but OEM parts look and perform much better...
Ive tried those Ebay projectors and theyre all junk. The seal of the housing is very poor. If yor going to keep them i suggest doing the DIY oven thing and resealing them with your superglue or something. (IMO waste of time but...)

Good luck

-EE

I know OEM is better, but obviously I don't want them on the car.

It's the covers that are inside the engine bay on the back of the housing, not the housing themself. The gray covers behind the bulbs.

I haven't had a single problem with water getting into the lights since I got 'em put on 4+ years ago, that's not an issue. But the covers have melted so bad that they barely stay on anymore. I don't want to just get rid of 'em and not have anything there to stop dust & crap from getting in.

I'll probably just take the lights off the car & try to rework the covers so they'll fit.

As far as the wattage. I'm not using a high wattage bulb at all. They're PIAA Platinum bulbs at I think 55 watts.

Well how hot do you think those bulbs get? Because they must be using polypropolene which has a low melt index. If you were going to go with another set of projectors I think it would be important to ask them what kind of plastic its made out of. Being in a plastic and polymer major, I learn about all this stuff. Unfortunitly theres not to much you could do with it already being messed up except order another set and possibly put ventalation holes on the cover.

Back when I had those crappy ass projectors, my covers melted too. I just left them off and didn't have any problems with dust and crap getting in and I lived on a dirt road at the time.

Hey bro, I had the same issues when I received my projectors. I have black housing (by Matrix). All 4 backs melted using standard bulbs. I just remove them when I drive and place them over the wholes when its garaged so bugs and shit don't get in there. I did go to the junkyard and got a pair of stockers (caps) I plan on using my dremel to make them fit. Other than that they are great projectors and don't leak!!