So I had some free time to change something up. I decided to take the plunge, I had 2 options based on the time I had. Either separate the housing and paint only or paint and retrofit projector beams. I didn’t have enough time for the projectors so only painting was done, another day projectors. Here is the final finish and assembled, the closest colour I could get(which is close to Zambezi silver) was aluminum. Took approx 3 hours from start to finish with the heat gun method, would have been faster with the oven methed.

 

Nice look!

 

Thank you Nodoubt.

 

Okay, how did you get the headlight apart?

I'm doing this. Today.

Love the look

 

A heat gun in low heat on the back side of the housing and 2 panel removal tools, or wide flat blades, work your way around the housing slowly.

 

How did you reseal?

 

Reheated the housing and pressed back into place, then went around the border and clip points with a thin bead of black rtv.