I'm doing my second headlight renewal in as many months and perhaps my sixth one in my lifetime.

After a thorough cleaning, I affix the lenses with butyl glazing tape. It holds and seals well enough to last many, many moons. I only wish I could find it in a 1/8" cord, that would be the perfect size to fit the groove in the reflector housing and it would save a lot of fussing around. Still, it works well.

The one hassle with renewing and, most importantly, drying out a 240's headlight is removing the moisture which is trap under the aluminum reflector glued to the bottom inside surface of the lens. I have been carefully cutting through the glue line with a makeshift knife made from .006 shim stock; I found out early on that a putty knife bitches up the reflector too much. I then reattach this reflector with the type of 3M double-sided tape which is used to install "inside" storm windows.

Does any one have any suggestions about how to dry the lens completely WITHOUT removing the reflector? Also, if removing the reflector is the only way to go, does anyone know what flavor of adhesive was used to attach it at the factory?


Thanks, one and all,
Rich