Robo Halo Headlight Mod instructions w/pictures

[dbest671]

Let me say thanks to bcarroll76, as this is part of his write-up that I expanded on.

The stuff you will need before taking apart the headlights:
• Pot holders that can be ruined
• Flat head screwdriver
• Phillips screwdriver
• Small paint scrapper
• Goo-B-Gone, Goof-off, or Krud Kutter—any of these will work
• Piece of card board to work on, so you don’t mess up anything.

Stuff you need to put the headlights back together:
• Goo-B-Gone, Goof-off, or Krud Kutter—any of these will work
• Latex gloves
• 3M Windo-Weld
• Caulk Gun for 3M windo-Weld


1. Pre-heat oven on 275 degrees(glass) or 235(lexan). I take off all mounting brackets prior to baking. Also you will want to take off the (8) little silver clips that go around the headlight. Just take a flat head screwdriver and they pop off from the bottom, just be careful because I fling them all over my kitchen. Also take out light bulbs.



2. Once the oven is pre-heated to 275(glass) or 235 (lexan), place headlight on rack and bake them for about 10-15 minutes. Make sure that the headlight is not touching any part of the oven except for the rack (obviously).



3. Once you pull the headlight out look at the corners, you want to find one where the glass or lexan has started to lift from the casing (usually where the level indicator is). Genteelly, put the paint scrapper in there and pull up. You are prying the glass off. You want to try and get it under the lip of the glass, NOT the rim of the glass. Lexan lenses don’t really matter because they are not prone to chipping. Once you got the glass up enough you can just pull it off. For lexan headlights, you don’t have to be as careful with prying.





4. This is the fun part, removing the factory glue. Keep the oven on. You will need the glue to be hot in order to remove it. Use a flat head screw driver and get the glue out of the channel. Others have used a #2 pencil. Some of the glue will stick to the glass, use “Goof Off” to get it off the glass. I suggest replacing the glue and NOT reusing it.

5. Clean off any glue that you may have gotten on the inside of the glass and put glass aside.

6. Removing the insert, remove the one black screw that is visible. The upper corner is held on with a peg, genteelly pull it up. The bottom is held on by two clips. You need to be careful if you are reusing the insert. You will want to grab where the openings are for the projection lights and pull towards you.


7. You will need to drill two small holes in the back of the bucket, so you can run the halo wires out. Make sure they are more towards the bottom of the bucket, so you can see the hole when you are trying to fish the wires through.