I was able to wrap this up today, I absolutely love how it came out.
All in all it went very smoothly. One of the studs that hold the headlight into place snapped right off as soon as I started to turn the nut
Everything was quite rusty so after that I was extra careful, but there wasn't much I could do. Getting the headlights out of the car was a real pain. I hate removing the grill on these too
With the headlights out I preheated the oven and got ready to bake them. 225 degrees for 20 minutes. When separating the two halves I got a little bit of the stringy silicone on the inside of the plastic lens... I used goo gone and a brand new microfiber and it came right off, but I'm not sure if your supposed to touch that part or not. Oh well, time to paint.
I used Dupli-color high temp semi-gloss black for the housings. Same as i used on my WRX lights. 3 light coats and it was good to go. I let it sit for a few hours before I assembled it back together
Now the high beams, I was a little unsure about. I almost even backed out and wasn't going to do them, but I gave it a shot. Masked off everything around and went to town. For this I used Dupli-color Metalcast yellow. Here is the first, light coat:
I did one more light coat and decided it was good.
One more thing I did before sealing the lights back up was adding a strip of butyl tape around the outer groove of the light. This ensures that it won't leak or have any condensation and also makes it so I can re-open the light any-time I want.
I stuck the lights back in the oven for 10 minutes to soften everything and was able to sandwich it back together and get all the clips in with ease.
All that was left was to hook the wiring harness back up and plug the bulbs in and slap them in the car. Which was a massive pain by the way. Anyway, final product!
Sooooo worth it!!