I didn't use a torque wrench but the Helm manual does indicate amount of torque to apply to some of the bolts (just the ones for the bumper - not the headlight assembly).

I don't think the way the headlight sits in the oven matters. Just put it on the damp towel so it won't tip over and accidentally touch some hot metal in the oven.

 

[QUOTE]Originally posted by Arnell
[B]...
I don't think the way the headlight sits in the oven matters.

 

Good point. In the summer months in Phoenix it's probably possible to put the headlight on the sidewalk for 20 minutes and get the same result!

 

I forgot the mention this. You said to get (2) 7440 bulbs and (2) 168 bulbs. I'm not sure what part you are refering to. So there is two bulbs under the amber or did you replace the other bulbs as well? If you did replace the other bulbs outside the amber why? I don't know whats under there yet, so your response would be great. Sorry for my lack of knowledge. Planning to start tommorow. Thanks.

 

Hope this is in time to help you out...

Both the 168 and 7440 bulbs are under the amber diffuser.

The running light is the smaller bulb in the bottom section under the amber diffuser. It has the 168 designation. (I noted above, though, that the 194 designated bulb works too.)

The turn signal light is the larger bulb in the upper section under the amber diffuser. It thas the 7440 designation. I did not try other bulbs for this socket and simply colored the stock 7440 bulb.

 

i'm doing bumper removal right now. you noted to tug the bumper off. is this a upward motion? seems like something is stopping me from removing it in the areas under the headlights. i loosened the fender hooks, but seem to have problems under the headlight. thanks again.

 

Ha ha. Man I had to jerk that bumper off. I got it off. Thanks.

 

I started today and so far so good. I haven't completed the project because I got caught up on the game (NBA). I will finish up tommorow if I can find those light bulbs. I'm thinking all clear bulbs. Well I took some digital photos. They are not perfect so excuse my skills on this one.

Phase One:

http://www.roxspin.com/images/headlights/mavica.htm

I will take more pictures for the final product. Arnell, very good instructions thanks! By the way, you are right about the alcohol. I'm sipping on a beer after the hard work.

 

Arnell can't thank you enough for this thread.......FAQ material Schatten....do your job bro!!!! Matt 25 and I started at 12:15 PM today.....Ira came a few minute later for moral suport... and finished at 7:00 PM. If I were to do it again I'd go with 15 minutes in the oven preheated to 225. Did that with the second light and the sucker peeled right back. First was at 225 for 10 minutes and it was a MF'er.....put back in oven. Only other comment would be to bake it at 100 degrees for a few minutes (10) after it's put back together....turn signal and high bulb's removed. Turn the opening up so moisture will vent out. The damp towel is great but introduces some moisture which needs to be driven out in a final heat cycle. I set the lights (one at a time) on a couple of hot mitts at 100 degrees. As for the bumper......when you know all the bolts are out....lift and pull!!!!! Scared the S*** out of me too! But when it comes loose....cool!!!!!!

I was gonna write an FAQ on this but Arnell has done a better job of describing the mod then I ever could. Follow hios directions and you are 90% there..........

Thanks again Arnell!!!!!!

Utah

 

True about the baking it longer, but I was a chicken $hit to bake it any longer. I just peeled it out. But yeah, follow the instructions and make you own adjustments if needed. Its pretty acurate! Good instructions.