Is there any kind of lip on teh headlights to use high pressure clamps all around to get that hulk tight seal?? what about heating up the silicone again when you're re-sealing so it gets all mushy and you know it's all melting together vs gunking new silicone on top of old?
using an oven with conservative times and temps followed by a heat gun (if necessary) would probably be the easiest in terms of opening to cut the time and hassle down to about 30 minutes or less...
great write up btw........can't wait to try it....
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