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Mitsubishi Evo: Faux JDM Headlights The 2003 Mitsubishi Evolution gets it's factory headlights transformed for that high-end Japanese "JDM" look. From "Tricked Out" episode DTRK-402

Black-housing JDM headlights. The real thing: $1000 or more. Our "faux" version: less than 10 bucks. The decision is yours.

In this Tricked Out project, a Mitsubishi Evolution gets some sharp custom accents without breaking the bank. Under the hood, host Andrew Totolos has already pulled out key engine parts and given them a powder coat finish. The plain metallic rims also got the powder-coat treatment, going from basic grey to brilliant yellow.

Now, in this second phase of the project, the Evo's standard headlights get a $1000+ "black-housing JDM" look at a fraction of the cost of the real thing. For less than ten dollars, he transforms the factory headlights into ones that resemble high-priced Japanese Domestic Market — or JDM — headlights.

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Materials and tools:

standard shop tools
oven
towels
cookie sheet
heat gun
rubbing alcohol
spray paint
silicone sealant

	Figure A
	Andrew places the headlights in the oven.

Faux JDM Headlights

• The first step in getting the headlights out of the Evo is to pull the front bumper cover off. This won't be necessary for every car, but it happens to be the case when working on the Evo.

• The Evo's bumper cover is attached like most, with a few fasteners around the edges and a bolt on each side in the fender well.

• After all the fasteners are removed, Andrew pulls the bumper cover forward and pops off the intercooler spare line to release the cover from the car.

• To remove the headlights, there are a few bolts to back out around the edges before pulling the housing forward (figure A) and unplugging the wiring behind the lights. Repeat the process on the other side.
  

  	Figure B
  	Once the headlight elements have been heated on low heat in the oven, they housing can be pulled apart.

• Andrew wants to access the chrome piece behind the headlight lens. To do this he'll place the headlight in the preheated oven in order to soften the glue so that the headlight housing can be easily separated.

• Preheat the oven to 225 degrees.

• Before Andrew puts it in the oven, he removes anything that might be affected by the heat. Stripping the housing on the EVO headlight is somewhat complicated because the HID bulbs have ballasts, which supply the voltage to spark the Xenon gas.

• Once everything has been stripped from the housing, it's time to start cooking. Cover a cookie sheet with a damp — not soaking wet — towel.

• Put the light facedown on the towel-covered cookie sheet.

• Place the cookie sheet with the part in the preheated oven.
  

  Andrew cleans the headlight housing components before they are spray-painted.

• After about ten minutes, remove the light from the oven.

• Now it's time to pry the lens from the housing. If the glue hasn't softened enough, use a heat gun to apply some direct heat to the more stubborn areas (figure B). Keep the heat gun moving. It can get hot enough to melt the plastic if it's directed at one area too long.

• Eventually, with enough heat and pressure, the housing will open.

• Once the housing is apart, pull the chrome pieces out and get them ready to paint.

• Lay out all the headlight pieces on your workbench, and clean them with rubbing alcohol to get rid of any fingerprints and/or residue.
  

  	Figure C
  	Andrew sprays the headlight housing with a special no-prep spray paint.
  	Figure D

• Most of the time, a piece needs to be sanded and primed before it can be painted. For this project, Andrew chose a spray paint that doesn't require this preparation work before it can be used.

• Apply several light, even coats of the spray paint (figure C). The first is a fog coat, and it should be applied as thinly as possible. This coat will provide a substantial layer for the thicker coats. After three coats, the parts look good.

• Once the parts are dry, it's time to reassemble the headlights. Make sure to clean any fingerprints off of the lens before reattaching it to the housing. Put a fresh bead of silicone sealant to the lip where the lens meets the housing and press it into place.

• Put the reassembled headlights back into the 225-degree oven for ten minutes to allow for a good bond with the factory adhesive.

• Remove the headlight from the oven and press the lens against the housing to make sure the bond is tight and permanent.

• After the housing has cooled, reinstall the electronics.

• Reinstall the headlights and reattach the bumper cover (figure D).

The Bottom Line —
Powder-Coating Engine Parts; Powder-Coating Rims; Faux JDM lights:

powder coating kit $180
no-prep paint $8
silicone sealant $5

Total = $193

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular car or truck, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit or replacement part that you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Safety Alert: Always wear eye protection and follow proper safety precautions when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle or working with caustic or dangerous chemicals.

RESOURCES :

Special resources for DIY's Tricked Out 400 series

Racing Innovations
www.racinginnovations.com

Knoxville Dragway
www.knoxdragway.com

Wetherill Associates
www.waipowdercoating.com

SPC Performance
www.spcperformance.com

AEM
www.aempower.com

Kicker
www.kicker.com

Autoloc
www.thehoffmangroup.com

Killer Cans by Alsa Corp.
www.alsacorp.com

Rapido Group
www.rapidogroup.com

Stellar Security
www.thehoffmangroup.com

Dyno Dynamics
www.dynodynamics.com

Stillen
www.stillen.com

Skunk2 Racing
www.skunk2.com

Injen Technologies
www.injen.com

Nitrous Express
www.nitrousexpress.com

Synapse Engineering
www.synapseengineering.com

Air Ride Technologies
www.ridetech.com

Airgasm Kustomz
www.airgasmkustomz.com

Lincoln Electric
www.lincolnelectric.com

Mickey Thompson Performance Tires And Wheels
www.mickeythompsontires.com

Buggies Unlimited
www.buggiesunlimited.com