Foglight Restoration/Modification

[Maxzillian]

In the case of my car, the fog lights and marker lights were downright pitiful to say the least. In comparison to a new car they were hardly adequate for interior lights. Now granted, one had a leak from two rocks punching a couple small holes in the lens, but from what I noticed from my good foglight, just about any can benefit from this.

 

To start things off, we need to upgrade to a bigger bulb than the 168 (on the left). Here's one that has the right socket, is bound to pump more light, but is just a hair too large to fit.

http://www.maxzillian.com/starion/lights/lights1.jpg

 

http://www.maxzillian.com/starion/lights/lights2.jpg

 

A pocket knife or anything useful for shaving plastic can do the trick. It doesn't need to look pretty, but you do need to leave enough for the bulb holder to grab on to.

http://www.maxzillian.com/starion/lights/lights3.jpg

 

http://www.maxzillian.com/starion/lights/lights4.jpg

 

And it even clears the lens... by a little bit.

http://www.maxzillian.com/starion/lights/lights5.jpg

 

On the passenger side is the 906 bulb, on the driver side is the 168. A slight difference, but more can be had.

http://www.maxzillian.com/starion/lights/lights6.jpg

 

If you noticed, the factory setup uses what looks to be a silver paint to serve as a reflective surface. Effective, but the paint deteriorates and there's always something better. Like this, at a whopping price of $5.

http://www.maxzillian.com/starion/lights/lights7.jpg

 

Here's a foglight assembly on good condition.

http://www.maxzillian.com/starion/lights/lights8.jpg

 

Here's the sort of thing that happens when one is exposed to too much moisture.

http://www.maxzillian.com/starion/lights/lights9.jpg

 

It's amazing the bulb even managed to find a ground.

http://www.maxzillian.com/starion/lights/lights10.jpg

 

To remove the lens requires a lot of patience. It helps to use an exacto knife to score around the lens to break up the adhesive used to seal it. Take a small screwdriver and shove it down near a corner of the lens so that the screwdriver is under the lens and not just catching the parting edge. If you pry on the parting edge, it'll break out and send glass shards all over the place. Gently pry at the corner until the lens begins to lift, then move to another. Do this slowly and you should be able to slowly get the lens to lift out.

 

The first step is to sand all the surfaces down to remove any deteriorated paint and clean it off using a solvent. Cut the tape into small strips and fit it in the parking light spot. Usually about 6 pieces can do the job. Some small strips here and there to fill in gaps. Also, in spots such as near the bulb where a flat surface won't work, it's helpful to put cuts in the tape so it can overlap itself. I also like to seal the edges with some superglue as the tape adhesive isn't very strong.

http://www.maxzillian.com/starion/lights/lights11.jpg

 

The same can be done for the foglight reflector.

http://www.maxzillian.com/starion/lights/lights12.jpg

 

Here's a completed assembly. Notice the strips around the foglight reflector. This doesn't necessarily improve the visibility with the foglights as much as it makes them look a little better when they're turned off.

http://www.maxzillian.com/starion/lights/lights13.jpg

 

Case in point... Before:

http://www.maxzillian.com/starion/lights/lights15.jpg

 

And after: (notice the spot in the upper right where the lens had damage from rocks. This was filled in with clear silicone to seal out water.

http://www.maxzillian.com/starion/lights/lights14.jpg

 

Now for the real test. On the passenger side is the 906 bulb in the good housing. On the driver side is the 906 bulb in the improved housing.

http://www.maxzillian.com/starion/lights/lights16.jpg

 

And the foglights. Improved on the driver side. I can't do a head on shot as it floods out the camera.

http://www.maxzillian.com/starion/lights/lights17.jpg

 

All in all, this should cost well under $10. $5 for the tape and $3 for the bulbs. Enjoy!

Edited September 18, 2010 by Maxzillian

[Maxzillian]

A friend brought up that the new setup may drown out the turn signals. Thankfully, they're still a-ok.

http://www.maxzillian.com/starion/lights/lights18.jpg

[Blind_Drifter]

Bravo. I love how to's/ Maybe ill go to my dad shouse tongiht just for that lol. You resealed with clear silicone?

[Maxzillian]

I could have, but I didn't. There was enough of the original sealant left that when the lenses were pressed back on, they seemed to seal up. If they start leaking, I'll reseal them with silicone.

[JustPaus_88TSi]

Take the bulbs and harness out, plop them into a preheated oven at 250 or so for about 5 minutes. They'll reseal.

 

 

I personally use a heatgun, but the oven will work also. And it's not enough time or heat to allow an "out gassing" and stink up the kitchen/stove.

 

 

Also, the best thing i've found to reseal headlights/taillights/foglights is windshield sealant made by 3M.. Doesn't need any heat and remains plyable for years and years. :wink:

 

 

 

Good work Max. Those foglight reflectors were pretty bad with the rust. I've worked on a couple dozen of these and have only seen one pair that was worse than that.

[Maxzillian]

Take the bulbs and harness out, plop them into a preheated oven at 250 or so for about 5 minutes. They'll reseal.

 

 

I personally use a heatgun, but the oven will work also. And it's not enough time or heat to allow an "out gassing" and stink up the kitchen/stove.

 

 

Also, the best thing i've found to reseal headlights/taillights/foglights is windshield sealant made by 3M.. Doesn't need any heat and remains plyable for years and years. :wink:

 

 

 

Good work Max. Those foglight reflectors were pretty bad with the rust. I've worked on a couple dozen of these and have only seen one pair that was worse than that.

 

Thanks for the compliments! I'll have to try that oven trick once I get home and my mother isn't looking.

[Blind_Drifter]

Getting started on this right now. Again, thank you for the write up.

[shift1313]

great write up man! Its always nice to see that.

 

how come your fog lights are on and your headlights arent :wink:

 

jk

 

good work

[jwrape]

VERY nice write up. Good Job I like it.

[Maxzillian]

great write up man! Its always nice to see that.

 

how come your fog lights are on and your headlights arent :wink:

 

jk

 

good work

 

Because it's spechul!

[Fanta]

Hmm, why not just do the same to the turn signals while you're at it eh?

[Blind_Drifter]

What about installing those LED 906 bulbs instrad of those regular ones.

[Maxzillian]

Hmm, why not just do the same to the turn signals while you're at it eh?

 

It looked like the turn signals would have been a little harder to crack open and since they were still bright enough, I decided not to risk cracking the lens.

 

What about installing those LED 906 bulbs instrad of those regular ones.

 

Maybe some time down the road. What stores like Autozone stock aren't worth a damn. A friend of mine has tried them on his Caprice. He ended up finding a number of LED bulbs from a seller on ebay that uses a number of surface mount LEDs situated so that they shine from the side of the bulb as well as from the end so they actually make use of the reflectors.

 

Either way, that's a good $20 worth of bulbs that I'll just hold off on.

[Blind_Drifter]

saw the one that emits light from the tip and sides. On ebay for like $10. I thinkk im going that route.

[Maxzillian]

saw the one that emits light from the tip and sides. On ebay for like $10. I thinkk im going that route.

 

My friend seemed pretty impressed with them, but he has owned them long enough to comment about reliability.

[TexasQuest]

So I take it the bigger bulb won't burn up the socket huh?

[Maxzillian]

So I take it the bigger bulb won't burn up the socket huh?

 

Hasn't yet. Granted it just now hit 60F out, but I imagine the 55 watt bulb I have sitting in the foglight portion puts out more heat.

[jeff_87tsi]

I have done both my cars fog lights and have led replacements in one and i have lexan covers on both, i did use clear silicone and the 3m sealant and like with my cleared taillights i used the chrome paint after cleaning them up, removed the rust. especially on the taillights with more surface area i needed a smooth chrome replacement for the rusted reflectors. wet sanding and polishing with 1000 and 1500 grit on the glass surface took out the surface pits which is common on all the ones i have worked on. i like the heatguns as well but use with great patience and slowly as i have warped lens, not glass of course. i have run 55w bulbs since 91 and have never had any problems with the heat, now the wiring should be replaced and upgraded as it should everywhere in quests. then you can also do the mod to allow separation from the high low beam switch. i run additional fog lights on both my cars as well with headlight replacements so again better wiring and fusing is a must plus cleaning up and eliminating the fuseable links with modern wiring is much better. nice job.

jeff

[Jayton]

Or you could buy brand new foglight housings (without the harness) for about $40 each from the dealer if still available.

[Maxzillian]

Or you could buy brand new foglight housings (without the harness) for about $40 each from the dealer if still available.

 

I didn't even bother to check. The way I see it, why buy something new when you can refurbish what you have? Not to mention if the factory just uses silver paint, I'd rather go this route.

[notfried]

looks real...um...bright,man 8)

 

good job

[Bad2Rass]

I did something real similar to this a little while ago but I retro fitted some HID bulbs in the foglamp housing while I was at. Mine where in really ruff shape too.