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Discussion Starter #1
I took my headlights apart to do some modifications using the heatgun suggestion which worked well. Once you get it started it seems to pry apart fairly easily.

I don't like the idea of leaving the old sealant behind and then re-heating it to put the lens back on. It just seems like a perfect set-up for leaks down the road.

I picked up some Krud Kutter Ultra Power Specialty Adhesive Remover for about $5 at Home Depot..

Using a paper towel, I was able to clean most of the gunk off the clear plastic lens. Be careful though, these solvents can and will dull plastic on contact.

Then I dripped some all along the channel on the black housing and let it sit for about 10 min. The sealant becomes extremely soft and fairly easy to scrape out with a combination of flathead screwdriver, utility knife, and gentle finger pulling.

Just wanted to share as some people seem to leave and re-use the sealant and others (like me) want to remove as much of it as possible.

I've attached a photo of the solvent and also what the sealant looks like when removed.

Hope this helps someone.
 

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I'm gonna have to buy that crud cutter. Bet it works wonders on vinyl adhesive. Does it leave the surface clean and dry? Or do you do a final wipe with alcohol or something?
 

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Discussion Starter #3
I just let it dry and evaporate. I guess you could do a final wipe with alcohol if you wanted though. It's great stuff; seems like it removes just about everything.
 

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Discussion Starter #6
Haven't gotten that far yet, but I'm planning on using 3M Window Weld.

It comes in either a caulk gun tube, or in ribbon form. The ribbon needs to be heated. I think the caulk style might be easier to use.
 
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