Big Thank You to MGB281 for your recipe! 

I decided to give it a go today. Removing the bumper was very easy and I am shocked at how good the metalwork is behind the bumper.

I have to be really honest but the thought of baking my headlamp unit was a bit daunting! I removed the bulbs and placed it in the oven at 140 for about 7 mins. 
It was hot enough to have to wear gloves and I started to pry the lens out. You were right MGB281 I did have to heat it a second time before it  came out.
As I worked I realised that it was best to pry the lens and the seal together from the framework rather than try to pry the lens out of the seal. 
I cleaned up the inside and gave it a final polish with glass cleaner.

I had decided from the outset that I would reseal it with Tiger seal. I cleaned out the locating groove in the headlamp unit and ran Tiger seal around the groove. It pressed back in fairly easily. Once I had the screw back in and the locating lugs folded back on the lens I placed it in the oven at about 50 for 10 mins. This allowed the sealant to harden enough to be firm.
I then filled in the gaps so it was fairly smooth and watertight.  I will fit it all back together tomorrow and try and take some pics. 

The only snag I had was when I tried to remove the microscopically small side light bulb where the whole holder thingy fell apart as it was so brittle. With a bit of a bodge and some superglue I got it back in the right place. I plugged it in briefly to see that the bulb still worked and it did.

The bolts and screws holding the bumper on were as good as the day it was built so I don't anticipate any problems putting it all back....hopefully. We will see how long the lens remains clear!

Thanks to all that contributed. 

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