Post 7/02 e39 headlight success stories?

**burakol** · 12-08-2017, 07:56 AM

Hi,

Currently vacationing in the Philippines and working on my fathers e39. Bought some EvoxR projectors to retrofit his headlamps. To my surprise, he currently has a face lifted assembly that is post 7/02 which I believe is permasealed and unbakeable.

Unfortunately, finding parts here is not as easy even being used. I've been reading some posts on HIDnet and there have been some success opening a permasealed assembly. I also saw someone with an F30 that opened his with a heat gun and some prying tool.

It seems doable, and in my case, appears to be no other option but to tackle the job... I just wanted to see if there's anyone here in the forum that was successful in opening the assembly without havin to cut and replace the lenses, and if you can share some tips and advice. Thanks!

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**philly98540** · 12-08-2017, 08:25 AM

I have not yet seen anyone successfully remove the unbakeable lenses without destroying them. There are some interesting hook shaped knife tools made for cutting the glue though.

**burakol** · 12-08-2017, 08:45 AM

Originally Posted by philly98540

I have not yet seen anyone successfully remove the unbakeable lenses without destroying them. There are some interesting hook shaped knife tools made for cutting the glue though.

The more i read, the more i think it is doable... but i have not come across anyone who specifically worked on a latter e39 headlight... hence, i amwith an hoping someone has actually done it on an e39

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**geargrinder** · 12-08-2017, 09:00 AM

There's vendors who claim they can do it but won't divulge the method. IF they are glued with epoxy (which is what legend claims...) then epoxy can be degraded w/ heat but thats a crapload of heat for a plastic assembly, and usually requires some good force as well even after its been heated (unless you can really destroy it aka like acetylene torch hot). I think cutting has to be the method?

**burakol** · 12-08-2017, 09:05 AM

The sealing material appears to be silicone like, not a hard cured epoxy... i really dont have much option right now... if i cut it open, we dont have a lens to replace it with...

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**philly98540** · 12-08-2017, 10:11 AM

I think it's a cured urethane type caulk adhesive on the non bake able lights. Very tough and tenacious stuff but not solid like an epoxy.

**geargrinder** · 12-08-2017, 11:37 AM

You know I think maybe I was comfruzing a similar Audi headlight that's epoxied?

**auaq** · 12-08-2017, 03:16 PM

Destroying the lens is a pretty pain in the butt and takes time and a lot of effort. Plus, it gets nasty.

If somebody finds a way to disassemble the sealed lens without the need to destroy them thrn please share here.

**burakol** · 12-09-2017, 10:00 PM

Will be doing this tonight... wish me luck

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**nikh23** · 12-10-2017, 02:05 AM

Take pictures. Will be likely doing this shortly

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**computiNATEor** · 12-10-2017, 05:42 AM

I'd recommend replacing the lenses if that's at all an option for you. At these cars' age, the plastic lens is probably brittle and likely to crack, as well as covered in scratches and pitting from road miles.

**auaq** · 12-10-2017, 06:30 AM

Originally Posted by computiNATEor

I'd recommend replacing the lenses if that's at all an option for you. At these cars' age, the plastic lens is probably brittle and likely to crack, as well as covered in scratches and pitting from road miles.

Well, yes, eventually the lens will get replaced. The issue is how to get the original untouched, unbakeable sealed lens off of the headlight assembly without cutting it out. If there's an easier method to get the lens off cleanly then that's what I and others are interested to know.

**computiNATEor** · 12-10-2017, 06:42 AM

Originally Posted by auaq

Well, yes, eventually the lens will get replaced. The issue is how to get the original untouched, unbakeable sealed lens off of the headlight assembly without cutting it out. If there's an easier method to get the lens off cleanly then that's what I and others are interested to know.

Right, trouble is, the easy method is with a dremel. :/

**burakol** · 12-10-2017, 07:23 AM

Have you guys seen the video of the one opening his F30 headlights? Those headlights are bonded with what they call a permaseal... maybe something similar to what the e39 uses...

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**auaq** · 12-10-2017, 05:42 PM

Originally Posted by burakol

Have you guys seen the video of the one opening his F30 headlights? Those headlights are bonded with what they call a permaseal... maybe something similar to what the e39 uses...

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Post the link if you don't mind.

**Dking078** · 12-10-2017, 06:06 PM

I think part of the reason behind not being able to open E39 03' spec lights is due to the housing plastic composition itself. More specifically they seem ALOT weaker structurally than newer models.

I can easily break the channels holding the lens in. On top of that moving a tool in between the lens and channel is a serious challenge.

**burakol** · 12-10-2017, 08:10 PM

Originally Posted by auaq

Post the link if you don't mind.

https://youtu.be/LLSOEKl1t8U

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**burakol** · 12-11-2017, 12:20 AM

Originally Posted by Dking078

I think part of the reason behind not being able to open E39 03' spec lights is due to the housing plastic composition itself. More specifically they seem ALOT weaker structurally than newer models.

I can easily break the channels holding the lens in. On top of that moving a tool in between the lens and channel is a serious challenge.

Now I totally get what you are saying. The housing itself is prone to breaking... i think the key is heating ir on the backside before prying it open. Im wondering if i end up cutting the outer channel, would I still be able to seal the insides decently? In the situation I am facing right now, it is inevitable that i save the lenses... the asjusters are also broken so i really need to get it open...

I know these a way to change the adjusters without opening it but I dont have a long torx screw to use...

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**nikh23** · 12-11-2017, 12:38 AM

Are you able to find a set of halogen housings? If your ultimate plan is to replace the adjusters and the projectors, then find a pre 7/02 halogen housing for cheap(er) than xenon housings. This is what I did when I swapped in some hella g4 bixenon projectors.

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**burakol** · 12-11-2017, 01:11 AM

Finding parts here in the Philippines is next to impossible... the current housing is a halogen and the plan was to drop in an EvoxR projector and HID.

If I would have known that this housing were updated by my in-law, I would have sourced either an aftermarket or used before I left the states.

The only set Ive found so far here is a preface assembly, which is actually the spec headlight for his car... either I buy that one and do the retro, plus install an AE since that is one of the things he likes...

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