[1999mercv6]

After years of putting of I decided to finally reseal and clean and clear my headlight lens. I first cleaned and sanded my headlights from 100 grit to 3000 grit sandpaper. Then used my heat gun and softened up thr sealant. Once soft and warm mind you you may need gloves you need to start using a flat head screw driver so slowly pry the headlight housing from the lens. Once its slightly separated you should you your hand to pull thr rest of the housing from thr lens. Once pulled apart you need to use the flat head at a slight angle to remove thr old sealant. Once i removed the sealant i thrn cleaned the housing with some simple green to remoe any trapped dirt between the lens and thr housing. Then picck up thr lens side and use a razor blade or box cutter like me and expertly cut away at thr sealant remaining on thr lens. This will insure thr lens will seat properly on thr housing. Once you do that then let the lens and housing dry completely. Once it's dry you need to heat up the new layer of synthetic butyl rubber.(mine was 10.90 for a roll for 2 plus lights on ebay) and get it hot making long slow motions back and forth on thr housing once nice and warm start to press thr lens and thr housing together to start sealing. It will take a bit to make sure its aligned as close as stock as possible but doesnt need to be exact. When removing thr old butyl make sure you dont get it all over you tile floor making a mess and dont get it on your clothing when warm because it will stick so just have a mini trash can to you side. You will have to constantly heat up and squeeze the living crap out of the housing and the lens. Next you will need the clips tou removed prior to unsealing and place them on the original spots. I was missing most do to old plastic tabs beaking so i got 3 on one and 4 on thr other. I used some channel locks to pull it tohgether more easily. Once you clip the headlight together thrn you will need to do at least 2 more passes with thr heat gun and you bear hugging the assembly. Once you've done that thr reasealing part is done. I used a cerakote headlight restoration kit and its the best ive tested with polisher. It was 16.50 on ebay and very fast shipping because it was distributed by Walmart. Just follow the most thought out instructions and continuing with clearing the lens i used the oxidation cleaner wiped and cleared any left over oxidation on the lens once thats done. You use a microfiber towel and wipe all debris and residue. Thrn use thr provided gloves and wipe thr ceramic clear coat on thr lens and you can use wiping or swirling motions if needed to apply clear on all parts of the lens. Next if you have animals you eill need to put the completed housing off in a big box or away from dust and debris in the air and in your surroundings to keep any unwanted materials on your lens. This will insure it stays clear and long lasting shine. I put mine in a box and top my microwave away from my cat. I believe it dries in 2 hour but i waited a whole night before removing and reinstalling my headlight. I havent got a pic of my headlights on thr car yet but when i do ill post a pic. Of before and after if i have it. I also bought 100w led low beams and have a high temperature harness coming with smaller gauge(bigger for the beginners) wire for optimal flow and efficiency as well as my old ones have basically no insulation but the copper corrosion is keeping it from shorting
Hopefully someone finds it helpful otherwaise i just wasted 20 Min writing this. Yes its 100w pair or 50 watts each bulb but is stable at 35 w. I went with auxito 9006 was about 70 with coupon code and has fan for cooling thr heat sink. *Also If You Say You Dont Have Time To Do This Your Lying To Yourself Because I Did This From 920pm To12Am just yesterday the 16th with a full time job.

I'm no teacher but you may find some help looking at the pictures.

 

[NakaiCougarV6]

That's amazing to do! My headlights get a little bit of water seepage from the rubber and have been holding off from taking them apart and polishing inside because of the glue. Mine still are decently clear but I will definitely save your post for when I try to restore them. Thank you so much!

 

[1999mercv6]

Your welcome but stock is most likely butyl rubber as we'll, as it melted and didn't burn when heating the headlight or it being synthetic rubber not natural. It hasn't rained so I haven't tested for seepage through the cracks in the plastic but prior to doing all this I did 1k clear them to fill the cracks and then did all the sanding to even it out and make smooth. Tomorrow I plan to take some pictures of water it looks up close on my car with and without lights on. I also have to get more foam and flexible plastic for the panel gaps as I had to take them off because they were nasty.

 

[1999mercv6]

This was before

 

[SpaceCatsAZ]

Looks great! Just did mine too. A 3m ultra kit and a week of sanding. Wasnt as brave as you though lol

 

[1999mercv6]

That's great but I'm sure they aren't as bad as mine were because mine has lived in the conflicting florida weather for 23 years almost all the time in direct sunlight. I mean it had only took me 3 hours then again I'm 24. I also decided to put 100w LEDS from Auxito LEDs that are 9006 low beam. I upgraded to a smaller gauge wire and have some 14 gauge jumpers to go between the headlight and semi factory harness. With a heat protective sleeve.

Upgraded 9006 HB4 LED Headlight Bulbs 6000K White, 100W 20000 Lumens

https://www.rockauto.com/en/catalog/mercury,1999,cougar,2.5l+v6,1356498,electrical-bulb+&+socket,headlamp+socket,4056

 

[SpaceCatsAZ]

lol it took a week because I have a new baby son, and three other toys not because im old. 24 year old haze is haze.