How to open your headlights and tail lights
The process to open up most headlights is the same, here are some tips that should help for most headlights.
PREHEAT (very important to preheat) your oven to around 150 degrees F. While it is preheating, remove any screws on the backside of the headlight which hold the lens to the housing (if present). Once oven is preheated, place one headlight in the oven for ten to fifteen minutes. Remove headlight, then you can use a couple flathead screwdrivers to carefully pry the clear lens off.
If the sealant is not softening in the oven you might need to cut it apart using a dremel or oscillating tool. Many of the newer headlights use permaseal which has to be cut or is just harder to separate.
BE SURE not to touch the inside of the lens or the chrome housings as they will be perfectly clean. This will prevent you from have to clean or polish them later. Remove the inside bezel and swap out the amber lenses for the clear, in most cases they will need epoxied in.
To reassemble the headlight with soft sealant, place in oven for another 10-15 minutes, then clamp together and reinstall the screws. This should seal up your headlight for you, but I like to supplement with a nice bead of clear silicone all around the outside as well as a backup. Ideally you should remove all the old sealant and use some new butyl to seal up the headlights.
These are just generic instructions but it should be helpful for most headlights, there are alot of videos on youtube as well.
Most older oem tail lights are sealed with butyl which are easier to open.
PREHEAT (very important to preheat) your oven to around 200 degrees F. While it is preheating, remove any screws on the backside of the tail lights which hold the lens to the housing (if present). Once oven is preheated, place one tail in the oven for ten to fifteen minutes. Remove tail light using some gloves. then you can use a flathead screwdrivers to carefully pry the lens off. Put it back in the oven if it seems like its not coming off.
To install our clear lenses on the housings:
Start by protecting the clear lenses with painters tape.
Make sure to clean out the old sealant from the channel on the housings. Test fit the lens to make sure that nothing is in the way. Then stretch some butyl or retro rubber in the channel. Put just enough to fill the channel, stretch the butyl to make it thinner and fit correctly. Then put the housing in a pre heated oven at 250-275F for 10-15 minutes. Then press our clear lens on and let cool.
We advise against putting our clear lenses in the oven. We also advise not to clamp our clear lenses or if you have to, be very careful
These 2 video should be helpful. (3rd party videos)