Okay, I just completed a retrofit for the headlights on my 95 Blazer.

I have 4x6 headlights.

I put them in, and they look DARN good.

The only problem, THEY ARE CONDENSATING!!! >

I thought I had them things sealed up nice and proper.

I fiberglassed the backs of the headlights so there werent any gaps between the headlights and the projectors, and when I say I fiberglassed, I did like 4 layers. And then I used and epoxy to seal the glass back onto the headlights, and then siliconed around that even!!!

Is there anything I can do to seal them even more?!

Im about 10 seconds away from selling them because this is no bueno!!!!

 

I'd throw them in the oven at like 150* for like 5-10 minutes with no bulbs in them and try to dry them out. Check HIDplanet.com for better ideas though. (try my idea as a last resort)

 

What will that do exactly? Just allow the silicon to seep into where it needs to be?

 

If it is all sealed up and there is a small amount of water in the housings, they will fog up when the lights get hot. Putting them in the oven for a small amount of time will help evaporate the water.

 

The thing is... Im about 97% sure they are completely sealed. I don't really know for a fact that they are, and I don't know how to tell for sure if they are or not.

 

You sealed water/humidity inside them. Like Thogert said - bake them then install the bulbs to seal the water vapor out.
If you have a food dehydrator then make me some jerky & put the light housings inside afterwards to draw the wet air out.

 

What temp should I put them in the oven on? I don't want to bake the silicone off of them lol

 

Low n slow... maybe 125/130F for 20 mins.
Google it cause I don't want to be responsible for your headlights lol.

It's just to get the moisture to lift up & leave the housings.
Ever reduced a sauce for dinner? Same difference, heat it up so it'll steam & remove excess water.

Thinking about it I'd start at 100F for 15 mins with the housing upside down so the ports are facing up. If you have a convection oven turn that feature on, it'll help.

 

I'll do that tomorrow. Now, what if they aren't fully sealed? What else could I do to ensure that the seal is good and proper?

I've already got fiberglass, epoxy, and silicone. What other measures could I take to FULLY get these bad-boys sealed up for good?

 

The grommet/rubber seal that the bulb has is usually an issue. Make sure it's tight when you turn it into the housing. If the rest of the housing is sealed, then that's the bandit IMO.