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Discussion Starter · #1 ·
I suppose I could have put this in both 2 and 4 valve modular tech but its more of a general question.

Im trying to separate the lens of my 99-04 tail lights from the housing and am having trouble. I tried to do the oven method but the red lens is so thin that it starts getting soft and warping before it reaches a glue softening temp. I would try prying it at room temp but it seems to have a lip in most places that has a thin piece of plastic in the way. Id like to get the two apart with as minimal damage as possible. It almost seems like Ford used some kind of glue that is stronger than the plastic it is bonding.

I am also not confident about using my heat gun. Because if even heat didnt work I dont see that a higher concentrated heat will have any success. I see either unfixable warping or melting happening with a heat gun.
 

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Discussion Starter · #3 ·

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Sorry it took so long for me to see this thread.

If Ford seals the taillights in the same manner as they do with headlights, heat won't open them. The sealant doesn't melt until about 900 degrees, which will already destroy everything else.

Given the limited aftermarket options that most likely use rubber butyl (which will heat up), I'd recommend looking into hot knifing it and plastic welding it back shut.
 

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although the lights look similar, you're gambling if you think aftermarket lens are going to be an exact fit. You may get water or condensation in the lights if the fit is poor.
I hope it fits well and seals properly, or you just ruined two sets of taillights.
Those lights do look pretty sweet though!!!
 

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Discussion Starter · #9 ·
They are darker than in that picture. And they match the 3rd brake light great.
http://img263.imageshack.us/img263/5594/kodakcamera095.jpg
http://img291.imageshack.us/img291/2199/kodakcamera096.jpg
http://img210.imageshack.us/img210/8206/kodakcamera094.jpg
http://img228.imageshack.us/img228/1245/kodakcamera093.jpg

I think they would look better if I could get those dark rose lenses on the stock housings. It would make it look like a tinted and chrome turn signal Cobra Tail. Which we all know doesnt even exist.
 

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Discussion Starter · #10 ·
Just to update:

I took my new Dremel to my stock passenger tail. It was extremely tedious and smelled like nasty burning plastic. Go figure. I was able to get the two separated but I did it by ruining the lens so as to preserve the housing. It was late so I called it a night but tomorrow I will try to finish it. I cut the lens off but that still left material that was glued to the housing.
 

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And you're gonna do the opposite with your after market tails I assume?
Cut the housing away from lense? That should work good, I'd seal them with 5 minute epoxy though. You can keep going over the joint until it's basically smooth and the stuff will just drop into every little air gap. Much cleaner than silicon or anything similar.

If you have a blow torch quickly pass it over the epoxy and it'll pop all of the air bubbles.(must be a torch of some sort, the carbon dioxide is what pops them not the heat.)

Post pics when you're done!
 

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I agree with love2cruz in the sense that it's better to cut out the housing part than the lens part. However your resealing method will depend on the type of plastic the housing is made out of. Look for markings. If it's polypropylene (PP) plastic, then traditional adhesives and/or epoxies will not stick well enough, as it's a type of plastic that is very resistant to it. In this case you'd be better off plastic welding it back shut. If it's polycarbonate (PC) or acrylic, you're in business.
 

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Discussion Starter · #13 ·
All im using is the smoked aftermarket lens and the stock Ford housing. I like the look of the reflective surface in the stock housing. I also like the way the aftermarket lens has the clear smoked part carry over the whole bottom area. If things work the way I want I should have the sweetest looking 99-00 Cobra tails ever. I also do want to set up the wiring to have an amber turn signal. Ill probably use a chrome bulb for a cleaner look though.
 
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