I had a headlight go out on my Friday night, seems the bucket (assembly, whichever) on the right side started leaking and after it filled to the point it hit the bulb it was all over. Okay, so that assembly gets pulled so I can seal it, no major issue. Go buy bulbs (for standard bulbs wallyworld rox... $6 cheaper per pair than Autozone) and walk out to see what's entailed to change them... find there's no way to pull the bulbs without pulling the buckets... WTF!??
Come home, grab my Haynes (say what you will about Haynes manuals but they're more likely to have wiring diagrams than Chiltons) and look up the lighting replacements. Oh gee, swell, you have to yank the buckets to pull the bulbs for both the blinkers and headlamps. Read a bit more to discover that you have to pull every light assembly on the entire car to change bulbs. Thanks Ford!
Not only that but the buckets are held in with clips that require retaining ring pliers to remove. This just keeps getting better and better. Happily I've got needle nose pliers that will fit the holes in the clips, I can use those by prying the handles apart. Works fine on two of them but the third is at the bottom of the bucket and I need curved jaws to get into it. Oh damn.
Go on Harbor Freight's site and they have a pair that have swappable jaws for $5. This was Saturday night so I had to wait for HF to open the next morning. At 9 I'm sitting in the parking lot cranking Hell's Bells when they unlock the doors. Sadly the $5 pair was a web only item so I had to go with a set of five for a couple bucks more. Bring 'em home and discover that they're not designed to spread as far as I need but they're flimsy and I force them wider allowing me to get the clips off.
Bring the lights in the house and start diagnosing the problem with the right side assembly. Fill the lamp chamber up with water, put air pressure to it and find the seep. Seal it with goop and take it outside to cure. Sadly the water's not evaporating so I put a fan blowing into the lightbulb opening and left it. While it's drying my room-mate gives me a couple of HS lapping kits that run from 600 grit to 2000 grit. I had lamented not having polish or sand paper finer than 400 grit. Yay! Now I get to wetsand my lights!
Start sanding on the driver's side and go from 600 to 2000 in steps... after I'm done my headlamp is cloudy. Oh goody. Run from 800 to 2000 again and it's better but still milky. Grab my Never-Dull and use it on the lens. Looks better but still some cloud. Grab the carnuba wax and hit it with the wax and it looks a hell of a lot better. By now the other lamp's been out there drying for three hours. Can't see any moisture so I assume it's all good. Glue's pretty well set so I'm off to polish this one as well.
A rinse repeat of the driver's side on the passenger's side and put the new bulbs in. Go out pop the lights back in, clip 'em and fire up the headlights but it's day time so I can't see anything. They're on, I can tell that much. Go back inside and tell my room-mate how much better the headlamps look, walk outside again and the right side lamp is cloudy in the headlamp portion. What? Walk over, look and there's a fine haze of moisture on the lens on the inside.
It never ends.