I didn’t modify my RZR lights, but I’d assume disassembly is like many automotive style lights, which is either a heat gun and veeeerrrryyyy careful prying or a small dremel cutoff and a lot of time. I’ve done both and they’re a pain in the ass, but if you’re looking for full on custom it can be a rewarding project.
Pro XP Headlight build Questions
Has anyone tore apart the headlights on these to do switch backs/blinkers and demon eyes?
Debating on building mine, just didnt know what all goes into it for these.
I know a guy that goes by black pearl did but he didnt post any pics of the install or talk about how to do it.
(I know I can buy a blinker kit that replaces the headlights but id rather build my own.)
Debating on building mine, just didnt know what all goes into it for these.
I know a guy that goes by black pearl did but he didnt post any pics of the install or talk about how to do it.
(I know I can buy a blinker kit that replaces the headlights but id rather build my own.)
1 - 20 of 24 Posts
Yeah I’m wanting full custom, but I’m not daring enough to open my trucks lol
Just got a spare set of headlights to mess around with. Will post pics as I go, and give any tips if I can.
git these OEM Stocks for $100
git these OEM Stocks for $100
Sweet! If you’ve never done it before, patience is a required skill to complete the job. Don’t be afraid of beer breaks.Just got a spare set of headlights to mess around with. Will post pics as I go, and give any tips if I can.
git these OEM Stocks for $100
Oh yeah complete newbie to this lol… might be a bit between updates but I’ll post when progress is made
I added a poll to see what others thoughts are on headlight bezel color.
Leaving today to go on a riding trip, parts are supposed to be here Friday.
Think I'm gonna have to learn how to solder a little bit for the wires on the DRL boards, shouldn't be to hard though.
Gotta order some butyl rubber to reseal them as well.
I'm just gonna leave them black, its easiest and I dont really wanna take them anywhere to get them painted.
Think I'm gonna have to learn how to solder a little bit for the wires on the DRL boards, shouldn't be to hard though.
Gotta order some butyl rubber to reseal them as well.
I'm just gonna leave them black, its easiest and I dont really wanna take them anywhere to get them painted.
how'd you get them apart, warm oven, then gentle prying?
Yeah Oven at 260 degrees the “gently” lol pry with a plastic pry tool or screwdriver (what I used) put in for 7 mins, pry, and repeat until it comes apart. Also having 4 hands helps so have a friend handy. At the bottom of the headlight there is a section that’s not as tight as the rest and is easier to start at.
what do you do to clean the glue off? or how will you get it cleaned up for reassembly?
can't wait to see the finished product.
can't wait to see the finished product.
Where are you getting parts from?Got them apart this weekend, definitely a learning process! Also ordered the parts to do RGBW with turn signals and a demon eye.
Just scrape the old out with a screwdriver, its butyl ruber and they say it will actually mold in with the old so I scraped out all the old and will put new in once I'm finished.what do you do to clean the glue off? or how will you get it cleaned up for reassembly?
can't wait to see the finished product.
SpeakeasyUTV out of Utah. His name is Carlos, I found him on Facebook in the RZR PRO XP/TURBO R group.Where are you getting parts from?
Ill chat with him to get his info if anyone is wanting to do this or have him do it.
"EDIT"Just scrape the old out with a screwdriver, its butyl ruber and they say it will actually mold in with the old so I scraped out all the old and will put new in once I'm finished.
Scratch what I said, I was going off of info I had from other videos and forums on other headlights.
Carlos said these are sealed with permaseal, he tried butyl and they leaked like crazy with a water dunk test. He has been using RTV and taping off the joints to get clean lines. I will be trying this hopefully this weekend if not sooner.
I’m excited to see how these turn out."EDIT"
Scratch what I said, I was going off of info I had from other videos and forums on other headlights.
Carlos said these are sealed with permaseal, he tried butyl and they leaked like crazy with a water dunk test. He has been using RTV and taping off the joints to get clean lines. I will be trying this hopefully this weekend if not sooner.
Here is the rough idea of how to do these.
(Contact Carlos Flores @ SpeakeasyUTV for parts)
Im trying to get him on RZRforum.
What you will need.
OEM set of headlights
Plastic pry tool (screwdriver will work but will leave more scaring on the lenses and the housing.)
Torx bits/ ratcheting wrench
Oven @ 270 degrees
Nitrile gloves (keep down on finger prints and for RTV)
Rubber coated gloves (Headlights are hot coming out of the oven and provide more grip)
LED’s/wiring/RGB controller from Carlos
Black RTV silicone
Clamps
2nd set of hands (Grab a buddy to help you)
TIME and PATIENCE
Remove headlight from RZR
Best to start with a clean headlight so clean if necessary.
Place headlight in oven at 270 degrees for 7 mins. (DO NOT PUT HEADLIGHT IN WHILE THE OVEN IS PREHEATING)
Pull the headlight out of the oven
You will have to do this multiple times so leave the oven on.
I started at the bottom of the headlight where the corner of the LED going from top to bottom meets the bottom of the headlight. It seems there is a bigger gap there to get started.
Place the pry tool/screwdriver into the housing gap and try to get to the bottom of the joint where the clear lens is sitting and pry up on the edge of the clear lens.
Try not to pry side to side with the screw driver as it will gouge the clear lens and leave marks.
Place back in the oven once the headlight is cooling down and not working as well.
(repeat around the headlight until you get the clear lens separated from the housing.)
DO NOT TOUCH THE INSIDE OF THE CLEAR LENS OR THE BLACK INNER BEZEL WITH YOUR BARE HANDS)
Try to only touch the edges of the clear lens and the black bezel.
Scrape/cut the permaseal out of the gap and off of the clear lens before resealing with RTV (as best you can)
Once separated wrap the clear lens and the black bezel in saran wrap to keep dust out.
Unscrew the bolts holding the stock LED DRL boards on and unplug the blue cables attaching them to each other and the one going from the board behind the projector to the upper LED board.
Unbolt the projector as well if your doing a Demon eye.
Cut off the stabilizer pegs for the stock DRL boards (4 total – 2 on both ends of the board) get them flush as possible.
Carlos has installed 3M double sided tape on the LED strips.
Lay the strips in where the old boards used to be.
RTV the top side of where the factory plug comes in and allow to dry (Demon eye)
Place the Demon eye LED strip on the black bar where you just placed RTV
Wires that go to the outside of the headlight come through a hole directly below the big projector board. There is a plug on the outside of the housing that will need to come off.
Push the wires through the hole and add RTV in that hole.
Add RTV to the outside of the hole as well, make sure to get it around all the wires.
Use the supplied heat shrink where the cap used to go to help keep water out.
Glue 2 (2 gram) silica desiccant packets inside of the headlight (see picture, orange circles)
Bolt the projector back on if you removed for the demon eye.
(TEST LEDS BEFORE YOU SEAL THE HEADLIGHT BACK UP)
Resealing the headlight
Tape the front of your clear lens (Painters tape works good)
Fill the gap of the housing for the clear lens with RTV
Push the clear lens back into the gap (helps to start with the top corner as its angled.)
Clamp the headlight in 3 places to get the most even pressure and allow to sit until the RTV is cured.
Use a heatgun to heat up the clear clips and move them down over the housing clip.
Run a bead of RTV around the headlight joint and allow to cure.
Once cured cut off excess RTV for a cleaner look (the rzr body hides most lens joint anyway)
(Contact Carlos Flores @ SpeakeasyUTV for parts)
Im trying to get him on RZRforum.
What you will need.
OEM set of headlights
Plastic pry tool (screwdriver will work but will leave more scaring on the lenses and the housing.)
Torx bits/ ratcheting wrench
Oven @ 270 degrees
Nitrile gloves (keep down on finger prints and for RTV)
Rubber coated gloves (Headlights are hot coming out of the oven and provide more grip)
LED’s/wiring/RGB controller from Carlos
Black RTV silicone
Clamps
2nd set of hands (Grab a buddy to help you)
TIME and PATIENCE
Remove headlight from RZR
Best to start with a clean headlight so clean if necessary.
Place headlight in oven at 270 degrees for 7 mins. (DO NOT PUT HEADLIGHT IN WHILE THE OVEN IS PREHEATING)
Pull the headlight out of the oven
You will have to do this multiple times so leave the oven on.
I started at the bottom of the headlight where the corner of the LED going from top to bottom meets the bottom of the headlight. It seems there is a bigger gap there to get started.
Place the pry tool/screwdriver into the housing gap and try to get to the bottom of the joint where the clear lens is sitting and pry up on the edge of the clear lens.
Try not to pry side to side with the screw driver as it will gouge the clear lens and leave marks.
Place back in the oven once the headlight is cooling down and not working as well.
(repeat around the headlight until you get the clear lens separated from the housing.)
DO NOT TOUCH THE INSIDE OF THE CLEAR LENS OR THE BLACK INNER BEZEL WITH YOUR BARE HANDS)
Try to only touch the edges of the clear lens and the black bezel.
Scrape/cut the permaseal out of the gap and off of the clear lens before resealing with RTV (as best you can)
Once separated wrap the clear lens and the black bezel in saran wrap to keep dust out.
Unscrew the bolts holding the stock LED DRL boards on and unplug the blue cables attaching them to each other and the one going from the board behind the projector to the upper LED board.
Unbolt the projector as well if your doing a Demon eye.
Cut off the stabilizer pegs for the stock DRL boards (4 total – 2 on both ends of the board) get them flush as possible.
Carlos has installed 3M double sided tape on the LED strips.
Lay the strips in where the old boards used to be.
RTV the top side of where the factory plug comes in and allow to dry (Demon eye)
Place the Demon eye LED strip on the black bar where you just placed RTV
Wires that go to the outside of the headlight come through a hole directly below the big projector board. There is a plug on the outside of the housing that will need to come off.
Push the wires through the hole and add RTV in that hole.
Add RTV to the outside of the hole as well, make sure to get it around all the wires.
Use the supplied heat shrink where the cap used to go to help keep water out.
Glue 2 (2 gram) silica desiccant packets inside of the headlight (see picture, orange circles)
Bolt the projector back on if you removed for the demon eye.
(TEST LEDS BEFORE YOU SEAL THE HEADLIGHT BACK UP)
Resealing the headlight
Tape the front of your clear lens (Painters tape works good)
Fill the gap of the housing for the clear lens with RTV
Push the clear lens back into the gap (helps to start with the top corner as its angled.)
Clamp the headlight in 3 places to get the most even pressure and allow to sit until the RTV is cured.
Use a heatgun to heat up the clear clips and move them down over the housing clip.
Run a bead of RTV around the headlight joint and allow to cure.
Once cured cut off excess RTV for a cleaner look (the rzr body hides most lens joint anyway)
1 - 20 of 24 Posts
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