DIY Thread - Properly separating your headlights

[RichardCranium]

Ok folks, I've now mastered the art of separating these headlights from Tahoe's/Avalanches/etc. After getting absolutely owned by my last pair, I didn't look forward to splitting another new set. This pair is the same Amazon replicas that I had so much difficulty with last time, and I split each one of these in just 20 minutes.

FYI, these are sold by different vendors on Amazon for around $100. Both sets I've had were tagged on the black plastic as VAIP branding.

 

[RichardCranium]

You'll likely need to rearrange your oven racks and take one out, you only need the lowest rack installed, on the very bottom slot. Take the others out so you can easily get your assembly in and out.

Preheat your oven to 275°, also place a large cookie sheet on the bottom rack, lined with aluminum foil.

Remove ALL of the wiring harness, light bulbs, and dust covers.

 

[RichardCranium]

Now place your headlights, lens down, on the cookie sheet. Set a timer for 10 minutes, and let it warm.

 

[RichardCranium]

When 10 minutes is up, take your headlights out. Do NOT grab the headlight by any of the tabs, they will deform and never be straight again. I recommend wearing some latex gloves, so you keep dexterity and get a little bit of break from the hot plastic.

I recommend picking up the headlight from the oven by sticking your middle finger into the running light socket. Use a rag though, since you'll be touching hot metal inside.

 

[RichardCranium]

You only need to work the inside part of the headlight......so around where the highbeam bulb is. Don't even bother with the outer portion, around the low beam.

Grab a flathead screwdriver with the widest blade you have. GENTLY insert the tip wherever there is a little gap, around the inside part of your headlight. Gently twist it back and forth to start a little bit of separation. You'll hear a little popping, which is what you want. Don't force the screwdriver at all, you'll deform the plastic and it'll look like a total hack job.

 

[RichardCranium]

You aren't going to get the headlight split after the first 10 minutes. Go ahead and know that.

After gently prying around the inside perimeter, you can try to pull the headlight apart with your hands. I highly suggest you place a towel between your stomach and the outside of the headlight, while holding the clear lens with one hand and your other hand on the black headlight backing. Pull your hands away from each other a few times, you might get a corner to start separating.

After a minute or so, go ahead and throw the headlight back in the oven.....lens down again.

 

[RichardCranium]

Take the light back out of the oven, again by the parking light bulb hole. Use your screwdriver again to gently pry around the inside perimeter. The butel is nice and hot, it'll be ready to come apart with your hands.

Hold the headlight as described before, and pull with a few strong pulses, adjust your hands and pull apart in different places on the inside of the assembly.

Both of my headlights came apart EASILY using these same steps, and only after two 10 minutes sessions in the oven. What a difference experience makes, I really wanted a lot of time trying to work ALL the way around the headlight last time. Total waste of time.

Hope this helps someone.

 

[kbuskill]

Take the light back out of the oven, again by the parking light bulb hole. Use your screwdriver again to gently pry around the inside perimeter. The butel is nice and hot, it'll be ready to come apart with your hands.

Hold the headlight as described before, and pull with a few strong pulses, adjust your hands and pull apart in different places on the inside of the assembly.

Both of my headlights came apart EASILY using these same steps, and only after two 10 minutes sessions in the oven. What a difference experience makes, I really wanted a lot of time trying to work ALL the way around the headlight last time. Total waste of time.

Hope this helps someone.

View attachment 191667

Nice write up with great pics... Well done and Thanks


Looking forward to the rest of your projector conversion thread.

 

[RichardCranium]

Nice write up with great pics... Well done and Thanks


Looking forward to the rest of your projector conversion thread.

Thanks, hopefully it at least can help one person. It isn't really the monster I thought it was originally, I was just doing it all wrong.

Hope to update my HID thread this week, pending time from work.

 

[01Konvict]

Nice write up!! @Jonah52 read this and split them yukons to delete the amber strip.