Hey guys... I purchased a really nice set of retrofit projectors for my 6gc.... I am wondering how people have removed the glass from the headlight housing without damaging the plastic or the glass... Any help is greatly appreciated!

Heat it up in the oven at around 200º F to soften the sealant.

http://www.6gc.net/howto/install_angel_eyes

"After 20 minutes of boiling, take out your lamp, and use a flat screwdriver to open the glass. Do it carefully, because you may break the glass if you don't. If the glass won't come off easily, boil the lamp for another 20 minutes."

The backing method is the best way to remove the glass.

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Backing method?

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I believe he ment baking

Lol, yeah, that's what I ment

You can melt the headlight if baked above 200F, or at 200F for too long, so be careful.

You could also do this with a heatgun slowly.

Some ovens have a "WARM" setting you could try first.

I used a heat gun for my retrofit! Keep the heat pointed at the glass not the plastic and SLOWLY used a flathead to pry it open.
I recommend that instead of baking or boiling, if you can, do it outside.. the oem sealant smells TERRIBLE and it likes to linger

If you need any ideas my retrofit thread is here: clicky, also feel free to PM me with any detailed questions

You've all been a great help... Unfortunately i ruined my OEM JDM projectors... well not really ruined but i wiped away some of the reflective coating on them while trying to make them... USDM spec. My next project is to well maybe take the lense out of the JDM OEM projector headlights and do something like smkr3w. Give it a more modern look with LED's... I don't mean to jack the idea but I like it. And i like it a lot.

I have ordered morimoto h1 projectors and im thinking up some ideas. I will post pics in my "project" thread on the progression.

Thans again for all of the help!

You've all been a great help... Unfortunately i ruined my OEM JDM projectors... well not really ruined but i wiped away some of the reflective coating on them while trying to make them... USDM spec. My next project is to well maybe take the lense out of the JDM OEM projector headlights and do something like smkr3w. Give it a more modern look with LED's... I don't mean to jack the idea but I like it. And i like it a lot.

I have ordered morimoto h1 projectors and im thinking up some ideas. I will post pics in my "project" thread on the progression.

Thans again for all of the help!

That's sometimes an issue with them. It's not the end of the world. You can paint the housing black or body coloured, or paint them in a metallic finish that looks similar to the original.

Im kinda wondering what color to paint the housing... Also I am wondering how Smkr3w did his vacuum forming technique...

Or pay somewhere that does chrome plating to do it. Wouldn't have to worry about it flaking off again.

if you plastics are just scratched, personally I'd rather paint them
>>also if you are using the jdm projector glass, i don't think the morimoto mini's line up right with it>>

BUT

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I bought thermoform plastic sheets from widgetworksunlimited.com -so far the only place I've been able to find them at a decent price.. except shipping is killer

prepped the back of the headlight housing to accept the smaller fitting of a shop vac.

then made a 12x18 frame with 2x4 stapled the plastic to the frame preheat the oven to 325, i believe it was. once its to temp set the frame in with the plastic facing up and keep a close eye one the plastic.. it will start to move and get wavy from the heat, when its perfect temp it will settle and begin to "droop." make sure you have headlight and vacuum ready to go. remove the frame wearing heavy work gloves set on counter/ floor/ workspace and while the vaccum is on, set the opening of the headlight on the plastic it will pull and form the hot plastic into the housing and then trim excess and finish little details..

mistakes i made:
-first used too thick of a plastic (1/16" iirc)
-tried a makeshift vacuum table that was terribly designed
-rushed it with not enough research

my final design that i've been running for a year now doesnt have a plastic shroud, I ended up using metal flashing from the hardware store and cut and shaped it to fit snuggly behind the projector.

eventually i plan on redesigning my headlights a bit

Hrmmmm.... I guess my biggest problem is the glass at this time... Where can i get a clear glass or good quality plastic lense?