TOYOTA SUPRA JZA80 HEADLIGHT LENS TUTORIAL

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Ross Townsend
6 years ago
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1 TOYOTA SUPRA JZA80 HEADLIGHT LENS TUTORIAL Disclaimer: Original Motorsports takes no responsibility for any errors which may occur in your DIY project. This is simply a guide. If you are not confident we recommend a professional installation. For off raod use only. Thanks to Richard from Spinto for his contribution.

Required Tools The following tools are required to complete this install -Black Automotive grade silicone, 150 C heat rate -Enclosed safety goggles -Vapor Respirator -Flat head / Phillips head screw

2 Required Tools The following tools are required to complete this install -Black Automotive grade silicone, 150 C heat rate -Enclosed safety goggles -Vapor Respirator -Flat head / Phillips head screw drivers -Silicone gun -Disposable gloves -Black double sided tape -Scissors -Dremel - cutting wheel / sanding attachment -Dust cloth / Microfiber cloth -Methylated spirits -Mechanic / protective gloves -Heat gun or hairdryer -Paper towels -Rotatable Vice / Clamp -Glass cleaner 2

3 Opening up the Headlights First Step is to open up your headlights. The silicone based product used in your headlights are heat activated. That means whenever it heats up over 70 C it will become soft and workable. Your headlights can be heated up using different methods. The two most common methods are by oven or heat gun. A hair dryer could also be used instead of a heat gun. If you use an oven, 80 C at 3-4 mins. Constantly check, as soon as it is hot to touch, take it out. Work fast, once it cools down, you will need to re-heat it. If you use a heat gun or a hair dryer, heat around the headlight when the lens will be pull off until hot to touch, if it cools down simply re-heat as you go. Pull of all metal clips on the headlight and KEEP THEM! DO NOT LOOSE! 3

Once you have enough gap, get your screw driver right under and gently

4 Use a flat head screw driver and gently but quickly work your way along the grove to seperate the lens from the headlight housing. Once you have enough gap, get your screw driver right under and gently lift the lens up. Continue this all around the headlight, re-heating when you need to. 4

it onto the gaps of your headlight housing where the lens will be

5 The lens and insert should come off together like this. Try to heat and scrape the silicone off your lens frame and put it onto the gaps of your headlight housing where the lens will be fitted again. Unscrew and gently pop out the headlight insert from the lens. 5

6 You should now have the three pieces seen in the image. Gently remove the rubber seals from the lense. 6

7 Using a flat head screw driver, scrape off the old double sided tape. Take off as much as you can to leave a clean surface. 7

Trim frames off lens Time to trim the frames off your lens. Here is where it gets a little tricky and requires your full concentration, First SAFETY.

8 Trim frames off lens Time to trim the frames off your lens. Here is where it gets a little tricky and requires your full concentration, First SAFETY. You WILL, need fully enclosed goggles and a respirator. If you can t get a respirator, at least a dusk mask. Wear a long sleeve shirt and mechanic or protective gloves. Make sure your working area is easy to clean up (garage or outdoors) with lots of ventilation. Using a vice to hold your lens into place. Make sure to use the correct cutting wheel with your dremel (reinforced cutting wheel) suitable for cutting metals. Other wheels may snap and become a hazard. You are looking to cut as close to lens as possible, otherwise the frames will be too short and your new lenses will not fit. It s not hard, you can see in the above picture that we are cutting right behind the lenses, even cutting a bit into them. 8

9 You should now end up with something that looks like this. You can see how close we have cut them. 9

10 Your frames should still have a small amount of the lens plastic. 10

11 Sanding and Test Fitting Time for some sanding. You can use your dremel tool (using sanding attachment) for this step for quick and precise work. Again remember SAFETY. Continue to work with GOGGLES, GLOVES, RESPIRATOR. Using the dremel sand off the excess plastic off the inside and outside of the frames. 11

Once you have finished sanding, test fit the frames on your glass lenses. If they don t fit flush check if there are any bumps on the frames, sand them back.

Don t try and use a filler their is no need and will in most cases ruin the adhesion of the silicone.

12 Once you have finished sanding, test fit the frames on your glass lenses. If they don t fit flush check if there are any bumps on the frames, sand them back. DO NOT over sand the frames or the lens will not fit properly. If they are slight gaps, it s fine, they will be filled will silicone. Don t try and use a filler their is no need and will in most cases ruin the adhesion of the silicone. Clean all your frames, lenses and seal properly in warm water with some dish washing detergent and a SOFT sponge or microfibre cloth. Then rise under water and dry. You can now fit the outer seals to help guide you when attaching the lenses. 12

13 Using black double sided tape, cut to size and stick to the seals. Make sure the seals are clean or the tape will not adhere correctly. The seals should look like the above picture once attached (front view). 13

14 The seals should look like the above picture once attached (rear view). The seals should look the above picture once attached. 14

15 *Your frames should fit like the above diagram. You will notice that the outer side and upper side of the lens is much larger than the inner and lower. Your frames should fit flush as the inner side and the bottom should only have a bit or no lip. 15

Attaching Lens For this stage of the process you will require the following by your side: *Silicone installed, ready in your gun *Paper towels or cotton buds *Methylated Spirits *Glass cleaner or a

16 Attaching Lens For this stage of the process you will require the following by your side: *Silicone installed, ready in your gun *Paper towels or cotton buds *Methylated Spirits *Glass cleaner or a cup of water *Towel, to put your lenses on You want to apply a nice thick amount of silicone around the frame. Add extra to any part of the frame where you had gaps. ( You want to slowly move the silicone gun around as you squeeze. The slower you go, the more silicone is applied.) 16

17 Your frame should now look like this. Position and press down the frame onto the glass lens. Look for an gaps. If there are any, fill them from the inside and outside of the frame and lens. 17

18 Now you can use the water/glass cleaner to smooth the silicone. Dip your finger in water, or if you have glass cleaner spray some on your finger (works best). Press down on the silicone with your finger and slide along the silicone. Keep wetting your finder as needed. 18

If you have any silicone on your glass it s easily fixed.

19 The silicone should look like this. Form a good seal and a smooth texture. Do the same to the outside of the lenses till it all looks smooth and filled. Make 100% sure that there are no voids. If you have any silicone on your glass it s easily fixed. Wet a paper towel or cotton bud with methylated spirits and gently wipe away any unwated silicone. Throw away and use new paper towel or cotton buds if you can see black silicone on them. Do NOT rub the methylated spirits on your silicone seal, as it will deteriorate the silicone. 19

Reassembling headlights Time to put your headlights back together! To keep them finger print free use deposable gloves while working with the headlights form now on.

20 Reassembling headlights Time to put your headlights back together! To keep them finger print free use deposable gloves while working with the headlights form now on. Using a micro fibre cloth and glass cleaner make sure your lenses are spotless. Then go over the glass with a dust cloth. Put the glass under light to check that they are spotless. Make sure your inserts are clean and dust free. Gently put your inserts back into your lens and screw in. Check again that no dust has entered the lens. 20

You want to avoid heating the headlights once the lenses are on, or you could risk fatiguing the silicone.

21 Make sure you have your headlight clips with you. Now your going to need to work very fast! Using your heatgun/hairdryer/oven, heat up the headlight housing until hot to touch. You want to avoid heating the headlights once the lenses are on, or you could risk fatiguing the silicone. If a certain part of the lens starts to get to hard to push in you will need to re-heat it. Do NOT use an oven, just try to heat up the headlight housing and push the lens in. Now install the metal clips around the headlight. 21

clips and add a bead of silicone around the gap where the

22 Let the headlight cool down. To be sure that no moisture enters the headlight remove the metal clips and add a bead of silicone around the gap where the headlight was opened Then re-attach the metal clips and leave the headlights to cure. Once the silicone has cured use black double sided tape or super glue to re-attach the rubber seals around the headlight. Now you should end up with this... 22

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS INSTRUCTIONS Accessory Application Publications No. SIDE 2008 CIVIC 4-DOOR All 37741 Issue Date AUG 2007 PARTS LIST Left side under spoiler Right side under spoiler 2 Side lower brackets The side lower