JDM to EDM headlight conversion

This article is about swapping the lightbeam reflectors of a set "one-piece JDM Headlights" to European lightbeam reflectors (with the exception of the UK, of course). I'll also show you how the lightbeam height adjustment motors are retrofitted into the JDM headlights and how to polish the lenses of the headlights.

Note: This is how I did this, following my instructions is your own responsibility!

Primary parts needed for swapping lightbeam reflectors:
•    Set JDM headlights
•    Set EDM headlights (or just the reflectors inside of them)
•    Hairdryer
•    Set screwdrivers
•    Black anti leakage sealant (for roofing / gutters, etc.)
•    Socket wrenches (size 8 is important)
•    Needle nose pliers

Additional needed supplies for polishing the lenses:
•    Wetordry grit 400
•    Wetordry grit 800
•    Wetordry grit 1000
•    Wetordry grit 2000
•    Wetordry grit 2500
•    Extra Whitening Toothpaste
•    Meguiar's Clear Plastic Cleaner
•    Meguiar's Clear Plastic Polish
•    Water

Additional requirements for the installation of height adjusting motors:
•    Set height adjusting motors (left + right, both taken from the EDM headlights)
•    (Battery) drill
•    Dremel (with accessories)
•    4mm drill
•    20mm spade bit
•    8 pcs M4 bolts
•    16 pcs M4 nuts
•    2 pieces rubber ring (inner diameter 20mm)

Original "one-piece JDM Headlights" produced by Stanley:

Use the hair dryer to heat the glue gradually in a particular area. At one point, the glue softens and you can place, for example, a point of a wooden clothespin between the lens and the black part to keep it open. Keep the adhesive gradually heated and try to open the lens gradually. It requires a lot of time and patience. It took me more than an hour to open just one headlight, not to mention that it must be done for four times...

Gradually heating:

Keeping it open with a screwdriver:

Almost open, just be careful with that part of the city light:

Fully opened up:

This EDM headlight was the next victim:

In the course of time, the lenses became dull and yellow. To make the headlights look like new, it is necessary to polish them and I have chosen to do this by hand. Start sanding the lens along the length (along the horizontal lines) with 400 grit. At a certain point it is clear to see where the coating on the lens is. Add water tot the sandpaper and sand the lens until the coating comes off and the lens is feeling smooth. You'll get the same result as in the picture below:

Each time before you go to another grit number, rinse the lens under the tap. Continue with grit 800 resulting in:

Then grit 1000:

Then grit 2000:

Then grit 2500:

Believe it or not, but in the next step I used whitening toothpaste in combination with a cotton cloth. Apply an amount of toothpaste on the lens and rub it over the lens until it becomes a bit more smoother:

For the next step, use Meguiar's Clear Plastic Cleaner with a clean cloth:

Last step for polishing. Meguiar's Clear Plastic Polish does just that beautiful extra gloss:

A great result, isn't it?

This section deals with the installation of the height adjustment motor as we are familiar with in the EDM headlights. Remove the reflectors from the headlights. This is done by turning the adjusting screws until the reflectors come out by themself. You're going to need socket 8, and the pliers to turn the lower adjustment screw (see image below).
The height adjustment motor needs te be in place of the lower height adjustment screw:

The screw comes loose when you remove the metal plate:

Close up:

Eventually you remove the following parts:

And this is what's left:

Remove the plastic using the dremel:

Make it flat:

Use the center of the hole to drill a 20mm hole:

So that the motor fits into it:

This is the motor. Note that there are differences in the position of the attachment points of the left and the right motor:

Put socket 8 on the upper adjustment screw (so the attachment points of the motor can't get in the way for adjusting the upper adjustment screw) and place the adjusting motor in the hole so you can mark drilling points, drill the 4mm holes, and place the bolts into the holes:

I took the rubber ring with the inner diameter of 20mm off a nut which is usually mounted on a junction box:

On the left the ring of the motor and on the right the ring from the nut:

Use some of the anti leakage sealant to glue the rubber ring:

Also use some of the sealant between the bolts and nuts to seal it all well:

Now let everything dry. If everything is dry, you can attach the height adjustment motor.

Remove the old sealant from the edges. You can do this by heating the old sealant and scrape it off with a screwdriver. Put the EDM reflectors on the adjusting screws and tighten themMake sure you have the proper reflectors in place! Clean the reflectors and the lenses with some glass/window cleaner, most likely this will be the last time you open the headlight ever again. Now fill the edges with the black sealant and attach the covers and lenses:

All that remains is to attach the metal brackets between the lens and the black part and the drying of the sealant.

Remove the bumper and install the headlights:

On this picture you can see how the motor is in the way of the parking light lamp. By removing the white cap from the brown plug it's all a tight fit. I also recommend to use a T10 LED light because the lifetime of the LED is in theory longer than an ordinary bulb:

The last two pictures of the final result:

All what's left is to get to a garage to get them properly adjusted.