E9X B3/D3 Headlight Refresh

[JohnW]

I was a bit sceptical how well it would work, so I purchased a used set of headlights from eBay to try. I had a spare afternoon today so cracked on with it.

I removed all the lamps and Xenon control box, covers, all the easily disconnected bits, then put the headlights in the fan oven at 80-100C for 10 minutes to soften the butyl seal so I could pull the lens apart from the headlight case. There’s a hidden torx screw behind one of the rubber vent tubes. They split quite easily then, the butyl turns to a chewing gum consistency when hot. But no need for gloves as it’s not that hot.

Using a flat blade screwdriver I removed most of the remaining butyl gunk, not as messy as I thought it would be.

Then I unscrewed and unclipped the old “celis” style angel rings and unscrewed the 2 chromed plastic bowls, sanded, plastic primer and sprayed them with matt black.
I refitted them with a decent set of LED angels I had, then I transferred the indicator holders and shrouds from the old to a new set of lenses (Chinese made) from eBay.

Next, I ran around and pushed in some new butyl seal into the channel around each headlights body, another £8 eBay purchase, then back in the oven and carefully press the new lens back on.
It took some careful persuasion, grips and clamps, but you get that satisfying pop when the each lens tab engages and that hidden torx screw tightened in stages helps pull the end back together too. Back in the oven again to bed in the butyl in place with the new lens.
Repeat for the other headlight.

Seems to have turned out quite well so far, not everyones cup of tea.

Part 2 will be dropping the front bumper to swap them with the original set, re-align the lights and treat with UV protection coating.