Guys

As a part of my AE and Xenon conversion (see my thread Halogen to Xenon Conversion - 2001) from standard halogen I had to sacrifice a post 10/02 headlight to get the Xenon internals. I took it to pieces with a reciprocating saw and rebuilt into the pre 10/02 unit.

Having finished my conversion job I had a play with the old case on the bench to see what it's like.

Firstly no way will this ever come open the same as a pre 10/02. As you know one is a type of soft mastic that melts easily, while this later adhesive is stronger than the black case and more akin to silicon sealer. It's stronger than the black case and resisted all the solvents I subjected it to including 24 hours with silicone eater.

I believe dissolving the adhesive due to the type and depth it's in the channel is a slim chance and if they have been opened it's due to force and probably damage

One suggestion is to try to get some old pre 10/02 NON xenon's from ebay and work from those. You can get them in the UK for around £30 a go so am sure they are available elsewhere (Here's an example on ebay.co.uk today currently at $2 with 24 hours to go under item 250137407879)

An alternative would be to cut the face off one unit as I did and you could then cut the adhesive out. Again you only need a scrap light to work from and there are plenty of theose with broken tabs around.

Not ideal solutions as they involve in effect using 2 units for each converted light, but an laternative to think about

If anyone wants me to experiment with anything on the sealant let me know. I'll keep it a few weeks.

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X5 3.0i Sport - Brembo rotors, Hamann Exhaust, custom Xenon & AE lighting, Retrofit Bluetooth
Z4 3.0i Roadster
CJ10a Jeep
TJ 'Challenge' Jeep