How to make clear corner lenses
- Plastic Stryene (Fluorescent Light Covering)
- Silicone Sealant
- New Bulbs (optional)
- Scroll/Band Saw
How To Do It
The removal of the following is not necessary, but will make the removal of the corners easier. It is possible to get the corners out without removing the headlights, it just takes some tricky socket work.
First remove the grille by unscrewing the four nuts holding on the grille. These screws are on the backside of the grille and use a 7mm hex socket to remove them.
Next remove the four screws holding on the headlight housing to the frame. The screws are located in the four corners.
Now the Grille and Headlight housings will be removed and you will be able to gain access to the clear corner lense
Locate the three nuts holding the clear corner lenses to the frame. Remove these three nuts to separate the lenses from the frame. Unplug the light bulb to detach the lenses.
Carefully crack open the lenses by separating the black backing from the clear lenses. Use an X-acto knife as a wedge to separate the lenses. Take your time and don't get impatient. The lenses are securely glued together and if removed hastily can result in a cracked lens. You will have to get another lens from a junkyard or have a cracked lens.
Take the Plastic Styrene and place the orange lenses on the styrene. Be careful to have the right side up or you will cut them out backwards, and have to repeat this step. Use an X-acto knife to trace the outline in the styrene.
To cut out the lenses I used a scroll saw. This was helpful because the plastic styrene is brittle due to the design pattern. If you use an X-acto knife, be careful because it will shatter easily. If you can get a jigsaw, scroll saw, or a band saw this will make it a lot easier. Take your time or you will have a cracked lens.
Try to fit the lenses and make sure they fit. If they are too big use a dremel or a sander to smooth down the edges. Keep test fitting until you have the right size and shape.
Place the lenses in and put the cover back on. Make sure the lenses can close. Use an X-acto knife to remove any plastic stuck to the black piece so they will seal correctly without any gaps to let in water. Seal the lenses with a clear silicone so any excess will be hard to notice if it gets on the clear parts.
Place the lenses back on and put the nuts back on. Don't tighten down to hard or you could strip the plastic or break it. Reinstall the light bulb. If you want you can leave the clear bulbs or replace them. You can put in a colored bulb found at your local auto parts store.
Simply screw them back on and connect the lights. You may need to adjust the headlights after this and make sure they are aimed correctly.