Fox T-Bird/Cougar Forums

So my headlights were almost completely useless.  I couln't even tell if they were on or off.  I think the previous owner used to sit with headlights on for long periods because the instrument lights are all burnt out as well.

Anyway, it used to be so bad, that I couldn't drive the car at night.  It was next to impossible. 
I sanded the headlights, re-aimed them, relayed them, and installed special summit high wattage lights in them.  Still no dice.

I finally disassembled my lenses and here is what I did to repair them.

Materials:
Paper, Scissors, Silicone, Shiny Tin foil, cotton rag, 3m Super 77

1. Split the lenses, and discovered the reflectors are pretty much completely gone.

2. Clean and degrease them.

3. Cut a template out of paper then transferred the template to the shiniest tinfoil I could find. 

4. Spray Super 77 inside the bucket.  Load it up good and heavy, this buys you some working time.

5. Lay the tin foil into the bucket and work it smooth.  I used a small piece of plastic wrapped with a cotton rag to do the smoothing. 

6. Use some silicone to glue the lenses back on and done.

I have no idea how long this will last, but dang. It seems to be working great now.  I can drive the car at night again!

I have a bunch of junk on my workbench, but the left is without the tinfoil (and the lenses removed) and the right is my new and improved tin foil modded headlight.  You can see the left is much better diffused and is definitely pushing out more light.  The right is highly concentrated and very dim.  The right side was actually much worse than the left.  It had absolutely no shine to it left.  So I figured I had nothing to lose on that one.


Some other pictures:

Hey good job! Way to think outside of the box! You will have to keep us updated on how long it lasts.

Pretty good fix in a pinch if you ask me... I wonder if you could have got a decent result using one of those chrome-like spray paints? At work I also sell an adhesive backed foil that comes in a roll.

I suppose for permanence they could eventually be re-plated with chrome if you remedy doesn't hold out long.

I figure this would hold over till I can find a good set at the JY.  My cars not really a show queen.  I am going to start looking at continentals as well because I hear they fit and probably led easier lives.
-Z

1988-93 Continentals use the same headlamps if that helps in your search!

good mod,, nice job.  never did it but i thought about it.

i used sheet metal tape on mine it dont smooth out real good but it helped alot.

What is the best way to get the lenses off?:bowdown:

bake it in the oven. Use a cookie sheet (one the wife doesn't mind you use) put it on like 200 degrees and let it sit in there for a few check it often and once it starts to come apart your done.

Thanks.:D

I just ran hot water over mine.  I pointed the hot faucet and then moved it over the edge I wanted to start with.  Then I used a butter knife and slowly pried it apart.  It was easier than I thought.

I used to couldn't drive at night either! My parking lights actually put out more light than my headlights!!!  I used the chrome spray paint in mine, and it worked great. I was going to use the tin foil as my original plan, but then I thought chrome paint would look much more natural (and be 100x easier). I didn't even have to work on getting my lenses off, they just pulled right off!! Combine that with a $20 3M headlight restoration kit and a power drill, and silverstar ultras and whaddaya get? HID's baby!!!!!!!!!

Chrome spray works wonders. I recently restored a set of used taillamps. I took the outer lens off and sprayed the bulb housing to restore the tarnished factory flat silver paint so it will reflect more light and I ended up with bright crisp red reflective exposure through the lens that makes a very desireable fresh look you cannot get with ordinary silver paint.

X2, used the chrome paint on a set of Cougar taillights, worked great, very bright.:D

I had messed with "chrome" spraypaint in the past and it just came out like sliver colored paint.  Maybe its better now.  Thats why I stayed away from it.  Maybe on the next set.  Pics!

Here's a pic of my old Cougar lights with the chrome paint. This is just the taillights on.:burnout:

While the paint never replicates chrome it does have a foil-like quality that regular silver paint does not have. I used the Duplicolor brand and I was impressed with the difference.

Yes, I used duplicolor as well, also in my taillights, and it was excellent, but, be warned, do not use it in any exterior area of your car, or any other area that recieves direct sunlight, such as mirrors, body, doorhandles...etc, b/c it will fade like the $3.00 junk that it is, and turn flat gray.

 I speak from multiple brainless experiences.

I had a feeling from the get-go that it might do that so I would never trust it for any exposed finishing in trim. For my interior I will stick with the Duplicolor Ultra Silver I used on extra trim pieces which I painted to match the factory aluminum dash trim on my Mustang. I have no desire but to use original factory trim colors on the exterior.