DIY: Headlight Lens Restoration

[lenny]

DISCLAIMER:
Wetsanding and Powertools should not be exercised on a vehicle by ANYONE but a professional. WORK AT YOUR OWN RISK
Okay, this seems to be a common problem with MK4 Jetta headlights I've noticed. The lens begins to fog up with road debris, fallout, and surface marring which really cuts down on night vision. There is a fix though and this is it.
Tools needed:
800 grit sand paper
1000 grit sand paper
1500 grit sand paper
Some sort of wet-sanding liquid (water, instant detailer, a light degreaser)
Cutting Compound of your choice
Polishing Compound of your choice
Optional tools:
Machine buffer, Rotary, or DA with pads (I used a PC7424 with 2 different levels of CCS pads)... Power tools will cut down on work time/effort required by exponential amounts
Various assortments of Torque (T25, T27) if you will be removing the headlights/bumper-cover
Some sort of paper-tape if not removing the headlights/bumper-cover
Here is a close up in detail of a lens that needs restoration. (this car only has 50,xxx miles but the headlights are subpar)
http://img.photobucket.com/albums/v453/lensch09/IMG_3019.jpg
http://img.photobucket.com/albums/v453/lensch09/IMG_3020.jpg
http://img.photobucket.com/albums/v453/lensch09/IMG_3018.jpg
Step one: If removing the headlight is not an option, be sure to tape around the lens to protect the paint on the vehicle (we will be sanding). Save yourself some time and effort by taking this step
http://img.photobucket.com/albums/v453/lensch09/IMG_3021.jpg
Step Two:
Begin wetsanding the headlights using the most course grit first (i started with 1000 grit but 800 grit would have been better). Be sure to go in a back in forth or up and down motion, DO NOT MAKE CIRCLES!
http://img.photobucket.com/albums/v453/lensch09/IMG_3023.jpg
Step Three:
Progressively move towards a finer grit of sand paper until you've reached the finest grit you have (I finished with 1500). The headlights will begin to haze over. DO NOT BE ALARMED, this is good. We will buff that out later
http://img.photobucket.com/albums/v453/lensch09/IMG_3022.jpg
Step Four:
Use a rubbing compound to slim down on the scratches/haze that have developed as a result of wetsanding. Again, go back and forth, DO NOT MAKE CIRCLES. (I used a PC7424 with Lake Country CCS pads (yellow and orange) and Pinnacle XMT#4)
http://img.photobucket.com/albums/v453/lensch09/IMG_3024.jpg
Step Five:
Use a polishing compound to get the finished look. (I used the PC7424 with a Lake Country White CCS and 3M Finnesse-IT2 Finishing Polish)
http://img.photobucket.com/albums/v453/lensch09/IMG_3028.jpg
(I opted to remove the headlights from the vehicle as I was not acheiving the results I desired while the lights were installed on the vehicle. The front bumper cover must be removed before you can remove the headlights)
Before and After:
http://img.photobucket.com/albums/v453/lensch09/IMG_3026.jpg
After Pictures
http://img.photobucket.com/albums/v453/lensch09/IMG_3027.jpg
http://img.photobucket.com/albums/v453/lensch09/IMG_3028.jpg
http://img.photobucket.com/albums/v453/lensch09/IMG_3029.jpg
After a bath and ready for customer delivery
http://img.photobucket.com/albums/v453/lensch09/IMG_3030-1.jpg
http://img.photobucket.com/albums/v453/lensch09/IMG_3031-1.jpg
Happy Detailing
-Dan

[SLugO]

very nice, i do this to all my headlights (the 3 pair i have)
you got faded, chipped pitted plastic lenses. this is your rememdy

[Kinderliving]

hey whats a rough estimate of material costs? I'm gonna help a buddy with his passat lights this weekend if he can afford the materials...

[SLK]

i should get on this, after i got my car back from the body shop i noticed my headlights are getting pretty hazy now.

[BimmerTim]

I just did this last weekend.

[The_Stig]

I just did this last weekend.
Yeah, and you're not even gonna post the pics? The difference was redonk

[shawn o]

The only problem with doing this is you sanded off the UV coating so not only will it haze over more quickly, it will also yellow due to the sunlight.

[lenny]

I did put on a coat of HARD wax so she'll be okay for at least a few months. I'm pretty sure the UV coating was gone anyways
-Dan

[Chimera]

The only problem with doing this is you sanded off the UV coating so not only will it haze over more quickly, it will also yellow due to the sunlight.

I'm going to guess that the pitting and road blasting took care of this a long time ago.

[RevMatch]

Hey are those the aero wipers that you have on your jetta? VERY off topic but I just wanted to ask: Where did you go about getting those? I've tried looking for them but haven't had any luck so far. By the way, nice job on the healights!

[Cracker]

I spotted this 3M kit at Walmart for $19. It's in the automotive dept by the touch-up paint and bondo. Kit included disc pad holder, 6 P500 sanding discs, 4 P800 sanding discs, 1 P3000 finishing disc, 1 buffing pad, 1 oz polish compound, and color instructions. You just use your drill with it, so no sore arms from sanding.
http://i14.photobucket.com/albums/a317/jasonrj217/IMG_0849.jpg
And after 45 minutes...
http://i14.photobucket.com/albums/a317/jasonrj217/IMG_0860.jpg
The kit has enough to do 2-3 headlights.:thumbup:
Here's a YouTube instructional video...
http://www.youtube.com/watch?v=_t1RBw0IGXA&feature=player_embedded
http://www.youtube.com/watch?v=_t1RBw0IGXA&feature=player_embedded

[bwolfgti]

I bought one of these for doing the headlights which seems to work well. Plus works good for waxing motorcycles or other hard to reach areas that a bigger buffer can't reach.
http://img.photobucket.com/albums/v513/bwolfgti/10794_FAM.jpg