Finally done the how to....
Bumper needs partly removed to get the lights out.

I used 8mm acrylic rod, round and solid, not hollow.
I got it from Ebay for about £7 incl. p+p.
LED's from Maplin, 3.6volt 5000 brightness, and 300 ohm resistors.

1. Remove all the bulbs and rubbers from the unit. Pay particular attention to the 2 screws (red arrows).

2. Pop the light unit in the oven, about 10 minutes at 150 celcius, probably about gas mark 3 or 4. Put ot on wooden blocks to stop it melting on the oven shelf.

3. Bend the tabs up whle they're still hot. Gloves may be required.

4. You may have to put the light back in the oven for 3 or 4 minutes before splitting the lens, trial and error here, but the hotter the glue gets the easier to split.

5. Once its apart, leave all the sticky stuff in place. Remove the 2 screws from the unit.

6. Use a peice of stiff wire to figure out where your going to place the angel eyes. Cut your acrylic rod to length, and pop it in the oven. Be careful and keep checking the rod to make sure they don't melt. Do one at a time.

7. Bend the rods, making sure they sit on the light perfectly flat. Good contact is needed for the glue to stick them perfectly.

8. Once your satisfied that the rods fit well, drill a 5mm hole in the end of the rod and using the epoxy glue stick the prepared LED's in. Leave to dry.

9. Drill holes or cut slits in the rods. About 3 mm into the rod from the back, not the front. I did my holes with a 3mm drill and about 3mm apart.

10. Using a 6 or 7mm drill, make holes in the light for the wires. Go easy, as the plastic is quite brittle.

11. The glue I used. Resin and hardener.

12. Clamp the rods on any way you can. Do a trial run with this first, it can get a bit messy if you try it with the glue and it starts moving about. The glue takes about 10 minutes to set solid. Remember to feed the wires through the holes you made.

13. Once you've stuck both on, test the lights.

14. My tester. A Nintendo gamecube power lead, with the gamecube plug cut off and 2 croc clips in its place.

15. Make sure the inner light and inner glass is completely clean, re-assemble it but leave the seal slightly open. Make sure to feed the wires for the angel eyes through the back of the light unit.
Put the whole unit back in the oven for 5 to 10 minutes.

16. Once its out the oven, push the joint closed and bend the tabs back down. Make sure the seal is completely closed, and the tabs are all holding the glass.
17. Make nice spade connectors for the lights.

Job done.

Wow

awesome, but i will not dare to put my headlight in the oven, knowing me, i'll probably melt it!

AWESOME!!!!

wow, looks realy good there mate

sorry buddy, but how did you connect the spades up? (or should i say what to? directly to your side light connectors on the back of the bulb?

I used piggy back spade crimped terminals.
Originally I had simply unplugged the side light connector and plugged them into that. But I now have LED side bulbs too,
which mean't I needed to splice inot the loom, just before the side light connection.

As an update to this, and something I'l lbe doing soon, put an LED in each end of the acrylic rod, not just one end.
It'l lbe much brighter and look better.

wow i might try this

neil i totally agree with you. i was going to put leds in both sides but i lost 2 of them leaving me with 3 so i could only use one on each ring,

i have wired them into the cig lighter with a switch below it, think when i take them apart i'll put a second set in onto of the main beam and wire them into the side lights.

thanks for the insperation so glad i did mine they look even better than the pic

Neil, so you re-used the original glue to stick the glass back on?

at step 15. " re-assemble it but leave the seal slightly open"
what do you mean by this?

I'm going to switch my chrome inners for the black ones like you have
but i'm affraid of putting my lights in the oven....

This just means leave it open BEFORE putting the light back into the oven. I'v heated the glue back up before re-sealing the join.

Will, the light will be fine in the ove, just use common sense mate. It really doesn't take that much heat to soften the glue, you only need enough heat to prise the light lens from the case. You'll find once you get a start, you can run round the light with a knife and cut the glue as you pull the light apart.

Thanks for clearing that up.

I opened one an hour ago hooray! Was quite a bugger.

Took out one screw (the lower one on the first pic), the other screw is attached to the clip and not to the glass? so didn't bother unscrewing it.

Put it in the oven @ 150 for just some mins and pried up them tabs. Scared at first but they were soft.
Then went back to warm up the glue (which nicely stays workable for quite some time) and popped of the glass
with some effort.

My oven is quite small tho, just got it in right with 1 cm space on each side. Your oven seems quite high!

Now there's 3 more lights to do....

Thanks Neil

Awesome guide, thank you

WOW realy owsome !!!!

im gonna have to try this wi my bj

Nice work there.. Can save me a lot of money