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I recently picked up a spare set of tail lights (thanks S2KPUDDYDAD) and a 3rd brakelight (thanks chitooneism from S2KCA) to experiment with. When baking the taillamps, for the most part, I followed the directions and experiences of other members who've baked them in the past and had great results. It was actually easier than I was expecting. I did chip/crack one outer lense, but luckily it was a small chip which can be repaired and will be concealed by the rear housing once it's all put back together.
My advice for anyone attempting this that hasn't been mentioned before is that the taillights should be separated from the inboard (inside most) portion of the lights first, proceeding to the outside. The outsides of the lights have a larger, more curved overlapping section which will be easier to slide out of position once the insides are separated. Additionally, some soft plastic, or perhaps balsa wood shims (something that won't scratch) are helpful in prying the plastic "clip and groove" portions.
Finally, the 3rd brakelight CAN NOT be baked and separated, or at least I haven't found a way yet. I was trying to separate the translucent red plastic from the black rear housing and electronics in an attempt to mold a clear lense for it. I tried multiple bakings beginning at 200 degrees for five minutes, increasing in increments of 5 minutes or 5 degrees at a time until I had baked the unit for 15 minutes at 225 degrees. All I managed to do was warp the entire unit (see pictures). Once I had conclusively determined that the light couldn't be salvaged I began drilling holes in the rear of the housing to see if I could determine what is holding the two pieces together. It appears as if the two pieces of plastic are actually molded together, in one process, around the electronics. Either that, or the glue holding the two together has a higher melting point than the clear outer lense.
So, as everything, this was a learning experience. Thankfully I got a great price on the brakelight. If anybody has any insight into how to separate the brakelight, please share.
Originally Posted by Jasonoff,Sep 19 2007, 06:05 AM
What does it look like on the reverse side? How are the metal studs attached?
The back of the brakelight is rather unspectacular. For the most part it's completely flat; the only holes leading IN to the light itself are the two small holes where the wires/plug protrudes in the center. I'll try to get some pictures in the comming days. The threaded mounting studs appear to have been molded into the black plastic, or they have been screwed in like woodscrews (doubtful).
I'm still caught up in the process of cutting up the brakelight I've ruined to determine if it will be possible to successfully separate another. When I have conclusive pictures, I'll share them.
I finally got some time to work on my little experiment, and took additional pictures of the third brakelight. After clearing away the foam insulation, it still appears that the studs can NOT be replaced (notice how I broke the end off trying to "unscrew" it from the housing).
This picture shows the end I broke off to try and determine if the two halves could be separated. It appears that there is only adhesive (or something) holding the two together on the very ends (where the black and the red come together). Whatever it is, it didn't want to soften with heat, and can't be cut cleanly with a knive. It could possibly be some kind of cyannoacrylic which "glues" by melting the two plastics together.
Finally, just for fun, here are a couple snaps of my first attempt at molding clear taillight lenses. It was essentially a complete failure (there are flaws everywhere, and I got the mixture wrong so it's still tacky to the touch after 4 days), but a learning experience, nonetheless.
A word of caution for the DIYers
