Butyl Headlamp Sealant is an automotive-grade sealing solution designed to properly reseal headlights after they've been opened for retrofits, repairs, or custom lighting upgrades. The flexible, durable design prevents moisture intrusion and ensures a long-lasting seal. Here's the recommended application process.
Watch the full video below, or scroll down for the step-by-step written guide.
Table of Contents
- How-To Video
- Tools Required
- Application Instructions
- Questions?
- Shop Headlamp Sealant at Ess K Customs
How-To Video
Tools Required
- Diode Dynamics Butyl Headlamp Sealant
- Oven or heat gun
- Scissors
- Locking pliers or clamps
- Oven mitts or heat-resistant gloves
Time Required: Approximately 45–90 minutes.
Application Instructions
Step 1 — Remove as much of the original sealant as possible from the headlamp channel. Clearing the channel allows the new butyl sealant to form a complete and reliable seal.
Step 2 — Heat the butyl sealant roll in an oven set to 200°F or lower for approximately five minutes to soften it. You can also use another controlled heat source.
Step 3 — Take a section of the warmed butyl sealant and stretch it until it's slightly thinner than the headlamp channel. The sealant should stretch easily when warm. If it gets too flexible, let it cool slightly before continuing.
Step 4 — Begin applying the butyl sealant into the headlamp channel. Apply enough material to fill the bottom radius of the channel evenly.
Step 5 — Continue applying sealant until the entire channel is filled. Cut away any excess with scissors. You should have enough sealant remaining to reseal a second headlamp.
Step 6 — Double-check the sealant placement, then place the headlamp lens back into the groove, pressing it together lightly. Using a baking sheet, warm the assembled headlamp in a conventional oven set to 250°F for 5–10 minutes.
Step 7 — Using oven mitts, remove the heated assembly and use locking pliers or clamps to fully seal the lens to the housing before the butyl cools. Secure the lens at as many points as possible, making sure all factory fastening points align correctly.
Step 8 — Allow the headlamp to cool at room temperature for at least 30 minutes. Once cooled, remove all clamps.
Step 9 (Permaseal Housings) — If the original headlamp was sealed using RTV or permaseal, install small thread-cutting metal screws (not included) at select locations to ensure long-term retention of the lens to the housing.
Step 10 — Once fully cooled, remove any excess butyl sealant by pulling it quickly away from the lamp.
Questions?
If you run into any issues, contact Ess K Customs — as an authorized Diode Dynamics dealer, we're here to help.
Shop Headlamp Sealant at Ess K Customs
Need butyl sealant for your headlight project? As an authorized Diode Dynamics dealer, Ess K Customs carries genuine products with full manufacturer warranty.
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This guide applies to Diode Dynamics SKUs: DD4048, DD4048X