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Tips & Instructions for XFasten Butyl Headlamp Sealant - 7 mm x 20 Foot

Butyl Headlight Sealant Tape Instructions

  1. Clean the surface and channel on the headlight edges where you would be installing the Butyl Headlight Sealant Tape. Lint, dirt, and dust can significantly lessen the bonding strength of adhesives. You can clean it with an alcohol solution. Scrape any residue sealant from the surface.

  2. Peel the tape from the roll. Cut the desired length of the strip based on the desired area.

  3. Slightly stretch the tape to make it thinner and more manageable and then apply the tape on the edges, gently pressing the butyl strip as you install it against the surface of the channel. If the butyl tape is thicker than the channel, you can stretch and flex it to fit it into the panel

  4. Cut the excess butyl and stick the starting point of the butyl to its other end.

  5. Further press and tuck the butyl in to prevent any air bubbles or gaps that may exist between the surface and the tape. This may cause the adhesive to weaken or water to build up over time. You can use your hands to squeegee any excess air.

  6. Heat up the headlight housing in an oven for 275 degrees Fahrenheit for 10-15 minutes, or until the butyl seal tape is soft enough to seal both surfaces. If the headlight is too large for the oven, then you can use a heatgun, albeit that would require significantly more time to soften the butyl sealant. Be careful when removing the headlight from the oven.

  7. Once the headlight housing has been removed, place the lens on top of the channel and press it firmly into the channel. Make sure to press it firmly to create a complete, airtight and watertight seal around the headlight.

  8. Reinstall any factory hardware to fasten the lens to the housing. If your headlight came with a permaseal and not screws, then it is a good practice to add in metal screws to make sure that the lens does not wobble or move over time.

  9. Clamp everything together using locking pliers or clamps all the way around the edge of the headlight.

  10. Put the headlight back into the oven for 5-8 minutes at the same temperature setting.

  11. For better protection against condensation, consider adding a few breather patches to improve airflow and prevent moisture build-up.

  12. Apply more strips by repeating steps 2-6.