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LAST EDITED ON 16-Nov-01 AT 07:22 AM (PST) (without pictures  -Isn't it odd how I answer a question to something I've never done to a person who lives in my same town...)
Here ya go Ryan:
1) Remove the headlight assemblies fro the car. This is done by unscrewing the plastic screws on the corners of the inner fender and the front bumper.
2) Remove the turn signals. This is done by unscrewing the single screw that holds each of them in.
3) Get a small ratchet and 12mm socket in the bumper cover and unbolt the retaining bolt that is right at the corner of the headlight and the front fender and the front bumper.
4) Unbolt the other retaining bolt that is located at the corner of the front bumper cover and the fender. This should make it fairly easy to bend the corner of the bumper cover down.
5) Unbolt the headlight assembly from the frame up top. There is 1 bolt on the very top, and there are 2 bolts and one nut on the backside of it.
6) Unbolt the row of bolts in the center of the bumper cover to get the bumper to bend enough. After doing this ot both sides, unplug the headlight assembly wiring harnesses, and maneuver it out.
7) Remove all the screws from the back of the headlight assembly itself.
8) Unclip all the clips around the assembly, and get a heat gun and a friend and a large flat screwdriver or pry tool, and CAREFULLY pry the lens off of the housing (the lens WILL warp if it is overheated and bent).
9) After you get the lens off, unscrew the orange reflector from the housing. Now, get a squeeze bottle of clear silicone, and apply in the area that the original bond was. Now, go in reverse with the heating process. Press the 2 halves together while heating then and applying extra silicone where needed. Also apply the clamps while doing this (this will help it stay together while bonding).
10) After about 30 minutes after you have put the lens back on, take the clamps off, and apply a SECOND layer of silicone around the lens where it meats up with the housing. Make sure there is NO spot where air or water can go through between the two. We recommend that you apply a third thin coat the next day just to make absoultely sure.
11) Wait 24 hrs before putting the headlight back onto the car.
NOTES:
- Try to keep all of your work neat (I.E. make sure when you re-bond the first time, that all the plastic around the housing where it lines up with the lens is as smooth as possible, and apply even layers of silicone).
-You now have clear corners, and a seal that is 9 times out of ten BETTER than your factory seal (not as resistant to impact though, which means that if you hit somebody or something and total out your car, your lenses will probably be laying on the ground past your car, but if you hit something that hard, the headlights will be your least of worries).
(COURTESY of ASOG- Edited for spelling, clarity and grammatical errors.)
Jason
98' Eagle Talon ESi-T
Mitsu Super 16g Turbo(HRC)/Custom FMIC
http://springfielddsm.homestead.com/JasonsPics.html
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Jason ESi-T
04' BMW 325Ci
91' Nissan 240SX
98' Eagle Talon ESi (sold)
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