Headlight/ Plastic Polishing How-To

[bugasm99]

Parts

Since I didn't have any automatic tools, I simply used a lot of elbow grease. Air tools and the like may make the job easier, but I do know it works this way for sure. Net cost: Approx $25.00.

1) Clean Terry Cloths (about 3)
2) Painter's Tape
3) Cloth Applicator (like you'd use to wax)
4) 600 grit wet/dry sandpaper
5) 2000 grit wet/dry sandpaper
6) 3M Rubbing Compound
7) Plastic Polish (I used Meguiar's PlastX)
8)Some kind of squirt bottle, filled with water and dishwashing soap (do NOT use car soap, it has waxes and such)

Procedure

1. Start by covering the edges of the headlight with painter's tape. This protects your finish in case you are a little too agressive with the sanding process. I find it easier to simply remove the headlight and work with it off the car.

2. Douse the headlight with soapy water. It is always better to use too much then too little. Once the headlight is wet, start sanding the headlight using your 600 grit sandpaper, continuously adding soapy water to keep the surface wet. You want to sand in smooth strokes using moderate to light pressure. The point is to uniformly roughen the surface.

3. When you are done with the 600 grit, the surface should feel slightly rough, but you should not be able to see any surface blemishes. The headlight will look VERY hazy.

4. Switch over to the 1200 grit sandpaper. Repeat step 2 with the 1200 grit. When you are done, the headlight will still look hazy, but it will be a little bit clearer. However, the surface should be totally smooth and free of any imperfections. Repeat steps 2-4 if there are still some surface imperfections.

5. Switch to 1500 or 2000 grit and repeat the process again. The lense should be pretty clear but still hazy.

6. Dry off the headlight with a terry cloth. Here comes the magic. Using the 3M rubbing compound, apply a quarter-sized bit to a new terry cloth. Work the compound into the headlight surface using hard pressure in circular strokes. Frequently turn the cloth and continue rubbing until dry. This requires a LOT of elbow grease; you will want to work the headlight until your arm feels like it's going to fall off and then some. It doesn't hurt to go over the headlight 2-3 times.

7. Then, apply the plastic polish. Using an applicator pad, work the polish into the surface using firm pressure and circular strokes. Once you have covered the surface, wipe clean any residual with a new cloth.

8. Your headlight lens should be MUCH better then it was. I still had some slight scratches in the surface from the 600 grit wetsanding process, so I did the whole thing over again and there was nothing left.

Please be careful. Do this procedure at your own risk, I can't be held responsible if I have made a mistake in the steps.

I am polishing a set of turn signals for a friend and should have some pics soon.

[GINA]

Thanks Josh, I've been wanting to do this. I'll have to give it a try in the spring though, it's too cold now.

[speedsk8er]

I'm going to do mine. But I think I'll try my dye drinder on very low speed with a light wool 3" auto buff pad... This has to be done very carefully, or you'll burn the lense... Great instuction's on the refinishing process...

Originally Posted by bugasm99

Parts

Since I didn't have any automatic tools, I simply used a lot of elbow grease. Air tools and the like may make the job easier, but I do know it works this way for sure. Net cost: Approx $25.00.

1) Clean Terry Cloths (about 3)
2) Painter's Tape
3) Cloth Applicator (like you'd use to wax)
4) 600 grit wet/dry sandpaper
5) 2000 grit wet/dry sandpaper
6) 3M Rubbing Compound
7) Plastic Polish (I used Meguiar's PlastX)
8)Some kind of squirt bottle, filled with water and dishwashing soap (do NOT use car soap, it has waxes and such)

Procedure

1. Start by covering the edges of the headlight with painter's tape. This protects your finish in case you are a little too agressive with the sanding process. I find it easier to simply remove the headlight and work with it off the car.

2. Douse the headlight with soapy water. It is always better to use too much then too little. Once the headlight is wet, start sanding the headlight using your 600 grit sandpaper, continuously adding soapy water to keep the surface wet. You want to sand in smooth strokes using moderate to light pressure. The point is to uniformly roughen the surface.

3. When you are done with the 600 grit, the surface should feel slightly rough, but you should not be able to see any surface blemishes. The headlight will look VERY hazy.

4. Switch over to the 1200 grit sandpaper. Repeat step 2 with the 1200 grit. When you are done, the headlight will still look hazy, but it will be a little bit clearer. However, the surface should be totally smooth and free of any imperfections. Repeat steps 2-4 if there are still some surface imperfections.

5. Switch to 1500 or 2000 grit and repeat the process again. The lense should be pretty clear but still hazy.

6. Dry off the headlight with a terry cloth. Here comes the magic. Using the 3M rubbing compound, apply a quarter-sized bit to a new terry cloth. Work the compound into the headlight surface using hard pressure in circular strokes. Frequently turn the cloth and continue rubbing until dry. This requires a LOT of elbow grease; you will want to work the headlight until your arm feels like it's going to fall off and then some. It doesn't hurt to go over the headlight 2-3 times.

7. Then, apply the plastic polish. Using an applicator pad, work the polish into the surface using firm pressure and circular strokes. Once you have covered the surface, wipe clean any residual with a new cloth.

8. Your headlight lens should be MUCH better then it was. I still had some slight scratches in the surface from the 600 grit wetsanding process, so I did the whole thing over again and there was nothing left.

Please be careful. Do this procedure at your own risk, I can't be held responsible if I have made a mistake in the steps.

I am polishing a set of turn signals for a friend and should have some pics soon.

[bugasm99]

Yeah, anything powered is a great way to get a clean and polished finish, you just need to be very careful which is why i chose to leave a rotary buffer out of this DIY. Last thing I need is people burning their lenses and blaming me for it.

[draco24433]

I was watching "Two guys garage" the other day and the guy used toothpaste, yes, toothpaste on the headlight. He rubbed it in with a little elbow grease. I could not believe as to how much haze the guy removed. I would suggest trying that before spending a dime.

[bugasm99]

toothpaste is actually a fairly good mild abrasive as it does have scrubbing elements to it. My only suugestion would be to do a test spot as i do not know how any of the other chemicals in the toothpaste would react.