How to fix fuzzy headlamps (Polycarbonate)

[macabethiel]

The most important / urgent item on my MoT list of work was under the heading "Repair as soon as possible" (Minor Defect).

Both headlamp lenses discoloured impairing efficiency.

I have see the various Videos and seen a raft of products that will restore them with lots of elbow grease.

Has anyone here actually managed it with a good result ?

[jims-terrano]

I’ve seen videos of people using toothpaste with bicarbonate of soda, arm and hammer is a brand that springs to mind.
There specially manufactured polishing kits for them too.

[elty001]

Many years ago when I had a Toyota estima that also had the polycarbonate lenses which where scuffed.
I bought a kit off of ebay which worked well but had to be done every six months or so to keep them clear.

[macabethiel]

Originally Posted by elty001

Many years ago when I had a Toyota estima that also had the polycarbonate lenses which where scuffed.
I bought a kit off of ebay which worked well but had to be done every six months or so to keep them clear.

That is interesting, I guess the basic restoration worked but the last stage that would be some sort of sealant to restore the shine did not contain uV inhibitors or they were not effective in the long term.

Most manufacturers went away from glass probably to save weight & money as well as allowing curvy shapes. As a matter of anecdotal observation the likes of Audi, BMW, Mercedes do not seem to suffer the issue as quickly compared to may of the cheaper Japanese manufacturers.

I am going to start with a basic wash & flatting with the fine Wet & Dry I have - 1200 Grit & 2500 then use Brasso with a buffing wheel. (Its slow but Brasso is great for removing scratches on watches glasses if they are plastic.) Then I am going to look at a branded sealant product with uV inhibitors.

I guess if this fails its buy a new pair of headlamp units - most are around £90-120 mark each for the WJ. I will see if any brands of sealnt are recommended here.

If it was still the same product I would buy a bottle of Klear Floor sealant - it worked a treat on bulling boots up in the 1980's!

[Rarche2002]

Do you want mine? I’m out there this weekend getting some bits off for elty001 not much effort to pull the headlights out


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[macabethiel]

Mine is a Jeep ??

[Rarche2002]

Originally Posted by macabethiel

Mine is a Jeep ??

Oh well mine won’t fit then
Unless you make them


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[Rarche2002]

I’ve actually restored a set of headlamps before on my skyline ended up just going through all the grits of sandpaper then finished up with a buffing wheel and mother’s cutting compound just gotta remember to keep it cold and wet or it will mess it up then I put 3 light coats of clear lacquer with uv protection on them


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[macabethiel]

I have taken some before photos and will post the stages as I go through the process.

The Jeep WJ headlamps are retained by a set of three clips (ball & cup type) and one long retaining screw so are really easy to remove. From my memory the wiring unplugs quite easily too.

It will be much easier to do the restoration with the lamps out - avoids masking & I can do the job on my garage bench where it is much warmer - and dry.

[kitchenman]

There is a kit on the market, got some in the workshop, I will check it out later and post details, neighbour has Nissan sports car, worked well on his so
I got a kit to use on my Honda scooter screen

[macabethiel]

This is the Jeep before I started - you can see the nearside lamp is more discoloured.
Before 1 by Teddy Bagshaw, on Flickr


Close up of the nearside Headlamp before I start the restoration process.

Before 2 by Teddy Bagshaw, on Flickr

[macabethiel]

First I washed the lamp unit thoroughly left lamp in place - will probably remove it when I start the sealant process at the end.

This was how it looked after 10 minutes of hand flatting with 1200 grit - its visibly worse (gulp).

First sanding by Teddy Bagshaw, on Flickr

[macabethiel]

Unfortunately its raining so after about 5 mins had to give up.
At least now its starting to look better again - wonder now if I should have used 2500 from the outset?
Its obvious from the uneven layering that the lamps have either been restored before or coated with a finish that was uneven and has now discoloured and worn off in places.

Plan is to give it some more hand flatting with 2500 Grit before I start the first Polishing with Brasso.

Need it to stop raining !!

After 5 mins with 2500 Grit by Teddy Bagshaw, on Flickr

[macabethiel]

Dried off the nearside headlamp and could see a strange sort of layered stain effect so with nothing to loose found a bottle of "Sticky Label Stuff" remover that we use to remove shop labels from various goods we have purchased.

Put a generous squirt of the fluid onto a cloth and began by wiping the whole headlamp lens area. This I know is safe to use on plastics etc from past use.

Within a minute all the stained / layer marks had disappeared, this stuff usually hardens adhesives gradually, it then removes the glue etc. At present the lens looks really good so I am resisting the urge to put on a finished layer - haven't actually bought anything yet though I do have an aerosol of clear lacquer. My worry is that it might mess up the polycarbonate surface.

Total effort time spent so far about 30 mins with probably 15 minutes of flatting with 2500 Grit.

Stick Stuff Label Solvent Cleaner by Teddy Bagshaw, on Flickr



So far my research has come up with a Turtle Wax headlamp sealing product at sensible price.

https://www.amazon.co.uk/Turtle-Wax-...NYK0H6P83DZVW8

[makeitfit]

Best thing once you've done with the polishing bit is a clear lacqauer.
Saves doing it again 6 months.
I've done a few now and easy with autosolve and a cordless drill and buffer. Takes several minutes max 😃