Tools:
-drill
-1/8 bit
-rivet gun
-1/8 x 1/4 rivets
-adhesive
-shop towels
-
Isopropyl alcohol or other solvent
-screw driver
-oven |
Difficulty
4/10
Time
2 hours |
Begin by removing all screws and retainer which hold your lenses and reverse sections in place.
- Place entire assembly in an oven NO WARMER than 175 degrees F for about 10 minutes
*IMPORTANT* ... do not leave the area... keep an eye on your oven in case your temperature is off!
-Remove from oven and use a flat head screw driver to remove your OEM lenses and then remove the reflector from the corner lens
-Once finished, you should have a bare housing which looks like this 
-Lay your lenses out, then sand or file the mating edges of each one so you get a semi coarse surface for the adhesive to bond to
-Clean the edges and mating surfaces of the lenses and housing with Isopropyl alcohol or other solvent
-Test fit your lenses on the housings to check fitment before commencing with installation
IF YOU FIND A LENS HAS WARPED IN SHIPMENT (first few shipments)
-Hold the lens in one hand, whole trying to avoid touching the face of the lens, use a hair drier to heat the lens up for 1-4 minutes in the warped area
-The lenses take two weeks to reach semi cure, and about one month to reach full cure. You will be able to straighten them up to that point.
-Once the lens has warmed up and is pliable, it will almost go back to its orginal shape
-Using your fingers, return it to the propper shape, and then if you have compressed air you can cool it off in about 10 seconds and it will retain the propper shape. 
-You will begin by installing the center lens ( L2 or R2 depending on which side you are doing)
-Apply a bead of adhesive on the top of the housing where the lip sits, as well as the grooves on top and bottom where it sets into place.
-Set the lens in place so the tab and hole line up on the bottom, and the two holes line up on the top

-Squeeze the top of the lens tightly into place while drilling a 1/8" hole in the center of the top lip though the housing
-Use a 1/8" pop rivet to hold the lens in place.
-Place one more rivet on each corner of the top lip 
-Flip housing upside down, and again while holding the lens tight to the back of the housing, drill a hole in the outer tabs
-Use pop rivets to secure finish securing the center lens in place.
-Now we install the L1 or R1 lens
-Again, begin by putting a bead of adhesive where the top lip sits, and then all around where the lens installs.
-Also, apply a thin layer of adhesive to the side of the center lens.
-Install the lens by sliding the pegs into the holes of the center lens while putting it into place. 
-Once again, squeeze the lens tightly into place, both the housing, and to the middle lens to close the crack between them as much as possible.
-Drill a 1/8" hole, and then pop rivet the lens into place on the top and bottom.

-When you squeeze the lenses together, some of the adhesive will come out the front. Use your finger and several clean shop towels to remove all the adhesive which comes out the front. It may seem tedious, but will come off and leave a nice finish.

-Now on to installing the L3 or R3 lens.
-Once again, apply a bead of adhesive on top lip mating surface as well as all around where the lens will mount.
-Also apply a small amount the other side of the center lens
-Slide the holes and pegs of the two lenses together while setting the lens in place

-Press your lens tight to the housing and the middle lense while making sure everything is lined up and drill your 1/8" holes
-Use pop rivets on the top and bottom to hold this lens in place as well.
-Use your finger and some clean shop towels to once again remove excess adhesive which squeeses out of the crack.

-For this step, I recommend removing the existing sealant that is in the housing. I left it in place for the other lenses as mine was still very sticky, and those lenses are held in place with pop rivets and not going anywhere.
-We want the best seal possible on this corner lens as no rivets will hold it in place.
-Use a flat head screwdriver to clean out the old sealant, and then clea it up with alcohol or another solvent

-fill the mating chanel for the corner lens nice and full of sealant to assure a good bond all the way around.
-apply a thin bead to the mating edge of the outside lens
-install the lens and line it with the outside lens
-use your fingers and shop towels to clean up the excess adhesive which squeezes out

-Once your adhesive has set up, go back over your lens, and fill in any gaps you may have missed during the installation
-You have a big tube of adhesive if purchased from me, so put it to use to make sure you seal your lens up well for a good waterproof, permanent installation.

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