The whole idea was to easier clean headlight lens and polish the…

The whole idea was to easier clean headlight lens and polish them once in a while.

Be warned if attempting to do this modification to your headlights, you will encounter following problems, so be prepared:

Once you get close enough to lens surface (polycarbonate plastic) you will notice difference
In lens clarity between old and freshly cut/ cleaned surface.

You will have to sand whole lens surface in multistep process, it worked for me starting with
400 -800 -1000 -1500-2000 grit wet/ dry sandpaper and then followed with foam attachment for rotary toll @ around 3000 rpm together with 3M plastic cleaner #39017 and final buffing with
Buffer and lamb wool.

The lens turned out crystal clear BUT now I was able to see what I couldnt see beforehand
And that was film on the inside of the lens, it wasnt from condensation, it looked to me rather some sort of glazing from halogen bulbs?

After unsuccessfully trying to take the film / glaze from inside of the headlight housing with water, last thing left to do is open headlight assembly the old proven way, backing it in the Owen for 10/ 15 min. @ Around 250 Fahrenheit and clean the inside of the lens with above mentioned 3M product.


I ended up purchasing new headlights anyway so I will have those for my free time to
Play with.

Good luck

Owner caption September 2009 · Photo 91 of 113