[billybob_81067]

Well in another post I explained how a bird hit my drivers side headlight and broke an adjuster screw and burned out my low beam. I got around to disassembling it today to find out what I needed to replace and lo and behold I found out that my headlight housing was melting!!! Probably due to my brighter headlights and also the fact that I've got a brightbox mod that allows both the high beams and low beams to be on when I have the highs on.

I pulled the other side off and it was starting to melt, but wasn't nearly as bad. Then I called the junkyard to see how much a new headlight assembly would be and they said 50 for a used or 75 for a new /ubbthreads/images/graemlins/shocked.gif. Not wanting to spend that much for another light assembly that I'd just melt I decided to fix these.

I started off by carefully prying off the lens of the light assembly with my pocket knife. then I cut a sheet of reflective aluminum to put on the top of the inside of the lights and a sheet of galvanized tin to put on the outside. Then I drilled holes through them and the housing and pop riveted them together. Hopefully the aluminum and steel will be able to take the heat much better than the plastic!

If I lost you with my explanation (I'm not very good with words) you can also just check out my webshots link in my sig. It's in the 95 powerstroke album.

/ubbthreads/images/graemlins/biggrin.gif

 

[iwantaturbo]

how do you get the head light out? i want to paint the trim but could not figure out how to get the light out?

 

[DBogo]

take both batteries out and both the screws are hidden in the radiatior support if i recall there 10mm or 11mm they just twist so you have to go back and forth between the two so it comes out straight or else it will come out crooked and strip out the plastic and watch out for those screws they are probably very very brittle from being in your truck all these years i snapped two of them off and not even the dealer had replacements because they perminatly mount on the rad support they dont come out spray em down real good with WD40 or your lube of choice or else you will find out how brittle they are the hard way like i did so i just use a machine screw seems to be doing the job for now

 

[billybob_81067]

yes, like DBogo said there are two screw/bolt fasteners that fasten into the back of the orange turn signal light. They are actually a stud with a coarse thread that screws into the back of the light housing, then a washer and then a nut that tightens it against the radiator support.

It took me awhile to find them but if you take the grill off you can see where they are from the outside and then try and find them on the inside.

 

[DBogo]

one more thing make sure you dont drop the socket down there its tough to get out

 

[PSDan000]

[ QUOTE ]
how do you get the head light out? i want to paint the trim but could not figure out how to get the light out?

[/ QUOTE ]

its a PITA to get them out...not a quick job to do. i did paint mine however with that truck bed liner crap, along with the grille...looks pretty cool /ubbthreads/images/graemlins/cool.gif