Custom Install Subaru STI-R clear lenses in Factory Qx56 Headlights

Eviltwin52s

New member
Joined
Apr 21, 2014
Messages
59
Reaction score
3
Points
0
Location
Kansas
GRRRR... Forum requirements is only 4 pictures...

I don't think I have seen anyone write up or even do a video of how to Custom Install new 3" Clear Convex Subaru STI-R lenses in place of the OEM lined lenses.

I spent multiple hours removing my old 2011 outer Headlight lenses, because they were in BAD Shape with spider cracks all over. Instead of paying $1200 per side for an entirely NEW Adaptive Headlights for both Left and Right. I went to searching Ebay and purchased broken housings that had no cracks or blemishes. Only because all of the local Salvage Yards wanted $600 each or more. So I picked up 2 of the 2013 QX56 lenses and began tearing them apart.

Here is a Pic of the clear lenses that I replaced.. tried to repair one with the Clear Lense repair kit where you use 6000 grit sand paper on a cordless drill and it was not pretty. I had fine scratches all over on the inside because the lens just has way to many curvatures to the face of it.

37293266005_fdb3b981e8_b.jpg


After tearing it down far enough to place the Headlight in the Oven for 7 min, at a pre-determined TEMP. I began pulling it apart and separating the lens from the Headlight bucket, using 2 screw drivers and multiple wooden paint sticks.

This is a PIC of the bucket with the Adaptive Headlight system removed. With both Chrome Turn signal and Clearance Light buckts painted black.
37293285935_85d679651d_b.jpg


Have you ever wondered just how many parts are in the Adaptive Headlight.. Well you no longer need to wonder.. Here is an exploded view of the Adaptive light/motor system.
37150091601_81e5344314_b.jpg


Before adapting the new 3" lens to the Stock Headlight system you have to do some tweaking of the outer aluminum ring. That holds it in place otherwise the new lens will move up and down. So a 2x4 and a small sledge hammer and you can begin to coax the aluminum ring to shrink its inner diameter to fit tightly against the convex curvature of the new lens.

I would have been done at this point. But after reading and viewing some DIY YouTube video's about HID aftermarket kits and STOCK HID they have a small lip that protrudes ever so slightly into the view of the HID bulb to create a shadow which causes your Beam Cut off to be less than the European Sharp cut off you see. So I began covering up the internal motor that turns the headlight left/right and out came the Dremel tool. After knocking off that small tab. You then have a very Sharp Cut off line.

36895494460_92b13742b8_b.jpg
 
Last edited:
Part 2 of Thread

One of the things I wasn't aware of, ever so slight but for the detail person... These Clear lenses for the Turn Signals and Clearance are actually frosted on the 2011 QX56 vs. 2013. So I pulled them out and put them in my 2011 Headlight buckets. :D

This is the original Turn Signal lens out of the 2011, you can see the outer part is frosted and rough.
37150047301_f2fa05e533_b.jpg


Here is the one out of the 2013, see how it is perfectly smooth and clear over the entire piece.
36478728363_e44c5c5644_b.jpg
 
Part 3 of Thread

Then lastly the Clearance light bits. Left frosted/Right Clear.
36895037480_89a1d2cb34_b.jpg


Lastly the inner Headlight bucket trim. I took my originals and they have been painted black and the Amber Turn Signal lens has been tinted black.
37150110181_679b0ce5d3_b.jpg


Once everything was completed, I then used some butyl rubber sealant tape and stretched it out around the groove in the headlight bucket. Placed the NEW clear lens on and placed back into my oven again for 7 min at the pre-determined setting.
When the headlight comes out, you have to work quickly to strap it down and screw the screws in so the rubber doesn't cool and push the lens apart from the bucket.

After multiple hours and the frustration of getting the black rubber butyl all over your fingers and the outer lens. I had to spend 20 min. just in cleaning up the outer lenses after installed to remove the butyl residue.

The end result my headlights plastic lenses are like brand new at a faction of the price of NEW. While improving my night vision, with a night and day difference from the original brightness. The new Cut off Beam is ridiculous such a difference less then 10 minutes makes in just removing that small tab on the inside of the HID headlight bucket.
 
Back
Top