3rd Gen BHLM + Retrofit Projector

I really want to attempt this.
Does the grill and bumper 100% have to come off?

 

Yes. There is 1 bottom screw (10mm) the is mounted inward connecting the headlight to the fender. Removing the bumper is the only way. Its actually really easy!

Got them all adjusted and wired up;
I'm LOVIN' this cutoff. super crisp, and not blinding oncoming traffic.
some night shots;


With the Highs on, it's super bright.
-The highbeam spot(h11) is getting swapped to OPT7 LED. Although I'm not super crazy about LED's.. with it being used occasionally, and momentary I think it will be fine. Finally, when I change out the fogs I don't think I'll even need a lightbar anymore.

 

Awesome job man n thanks for the details

 

I would bet getting the lens apart from the housing would be the most pain in the ass part.

 

I know you mentioned the bake time in your first post, but its a little confusing with the different times you had to use. Now that you have successfully got the perma-seal apart what temp and time do your suggest so that multiple reheating is not needed.

BTW the lights look AWESOME!

I did the VLED high beam and HID low beam conversion from the TRS, but I'm not 100% happy with beam quality thats why Im doing a retrofit like you.

Also I have a pair of baja designs squadron light on my BMW R1200GSA, they are AWESOME, you will not be disappointed. Its also really nice to see Baja Designs making an adaptor to fit their lights into the factory toyota fogs. It looks like I'm going to have to buy a pair of the he baja designs squadron racer lights.

And for those of you out there that don't understand the different types of lighting and the proper selection for what your using the lights for Baja Designs has a great read called the Science of Lighting. Check it out...
http://www.bajadesigns.com/page.asp?p_key=036E902AEE0340F2AB2042420B2611C7

 

I have read 2 different approaches on getting the permaseal to break free. Some guys bake it hot(270-280) for 8-10min. Others bake it longer 18-20min at a lower Temperature(230-240). I choose the later. I figured baking it longer would slowly heat up everything consistently, plus I wouldn't risk melting the housings.
After ~20min in the oven it was still hard to break apart. The plastic housing was malleable but the lens still wouldn't budge. So back in the oven, but I bumped up the temp to around 250 for 10min. This started softening things up, now I could get a flat head under a corner and start working it up. By the time I got halfway around, the housing had cooled. So I out it back in the oven 1 more time and that finished it. Good luck

 

Also, @sdsmtengineer I don't think you can do it in 1 bake unless you get the housing REALLY up to temp. Maybe the pros can, but multiple bakes are definitely advised. It's actually not bad; while your working on one, the other is in the oven. When your done prying, the other will be hot and ready and you can just swap them. Repeat until you crack em' open!

 

So much win in this thread. Great job.

 

I completely agree with @mesojdm. I initially thought multiple heatings would be annoying but it's really not that bad. If you try to race through it, you'll likely mutilate the black housing - it gets pretty soft even at 240. Take your time and enjoy some awesome custom lights.

 

Subd

 

My question is why did you cover the lense in tape to put in the oven? I've done multiple sets of headlights and tailights without covering the lens.
Your write up is amazing! Great job!

 

Curious as well

 

I didn't want to take any chances scratching the lens when man-handling it trying to take it apart. The plastic can scuff pretty easily. Cheap insurance, and it pulls right off leaving no residue.

 

Awesome. I woulda thought there would be some transfer from the tape or at least residue. I wonder if it also helps retain heat during the process.

 

This isn't related to the headlights but something I noticed in your picture of the headlights installed. Did you paint parts of your grill matte black? Or is it just the lighting in those shots?

It looks different in those shots from my chrome grill. Just curious.

 

The center grill section was removed and painted with black plasti-dip.(temporary)
This is how it looks now.
P.s I am LOVING THESE LIGHTS.

 

Beautiful

 

Thanks! It's a must have for the 3rd gen's and completes the look IMO.
What are you waiting for?: https://www.tacomaworld.com/threads/pair-of-tacoma-headlights.444108/

 

Good luck! I you for taking on a permasealed headlight as your first retrofit. Butyl is stupid easy compared to permaseal. I hope you get it man!!! I kinda want to do a set now