Fixed my yellow/cracked headlight today (pics)
I think those are the things they use to set the adjustment from the factory....i was thinking of getting rid of them, ut im waiting for someone else to do it first 
those headlights look great!!
those headlights look great!!
yellow headlight shells
Originally Posted by LS1 Sounds
Before:
After:
I had some pretty bad spiderweb cracks in this headlight so I had to remove a decent amount of material to get rid of them. I started out wet-sanding with 400 grit, then 800, and finished with 1500 grit. After everything was sanded smooth, I used a Novus 3-step plastic polishing kit ($11.95 shipped from Spa Depot).
It took me about 3-4 hours by hand, but I'm a perfectionist and stuff like this usually takes me a long time. If you decide to use any type of machine to do this, be careful... plastic is very sensitive to being over-heated. I only did the passenger side headlight, the driver's side was replaced not long before I bought the car due to the previous owner having an accident. I will probably pull the driver's side light next weekend and hit it with the Novus polish.
Here is an after pic:
Here are all of the pictures that I took showing the progress: linky
After:
I had some pretty bad spiderweb cracks in this headlight so I had to remove a decent amount of material to get rid of them. I started out wet-sanding with 400 grit, then 800, and finished with 1500 grit. After everything was sanded smooth, I used a Novus 3-step plastic polishing kit ($11.95 shipped from Spa Depot).
It took me about 3-4 hours by hand, but I'm a perfectionist and stuff like this usually takes me a long time. If you decide to use any type of machine to do this, be careful... plastic is very sensitive to being over-heated. I only did the passenger side headlight, the driver's side was replaced not long before I bought the car due to the previous owner having an accident. I will probably pull the driver's side light next weekend and hit it with the Novus polish.
Here is an after pic:
Here are all of the pictures that I took showing the progress: linky
LS1sounds, I have a few noobie questions, because I simply do not know anything about this type of work or the tools. When you say 800 grit, 1000 grit, 1500 grit, what is grit? Is it just different sandpaper?
Can you explain "wet-sanding" more for me. I don't know if it means to keep the light wet while you rub it with the "grit".
Also, is taking off the headlight hard and or safe?
Where can I get the proper polish for these headlights?
Thank you for any help you can give me.
Can you explain "wet-sanding" more for me. I don't know if it means to keep the light wet while you rub it with the "grit".
Also, is taking off the headlight hard and or safe?
Where can I get the proper polish for these headlights?
Thank you for any help you can give me.
Yes, the grit is (IIRC) the amount of particles per square inch of sand paper. The higher the number, the finer the sanding. The reason you start off with a courser (lower number) grit is to remove material faster. You could do the job with only 2000 grit sand paper, but it would take you for ever 
as the finer the paper, the quicker it clogs up.
Wet sanding is used a lot on automotive paint jobs as it removes the orange peel and gives that nice, deep polished look. By using water while sanding, it helps the sandpaper from clogging up so fast and also helps lubricate/polish/cool the surface being sanded. I actually sprayed a bit of WD-40 cleaner on my paper when doing it, but I wouldn't advise that.
The lights arent too hard to remove, any $15 dollar manual from an automotive parts store can show you how. There maybe steps/pictures already here in the forum's archives or on Install University's site.
The plastic Polish and sand paper can be purchased from most automotive paint supply places and even Pep Boys. Meguiers, 3M and others make the polish.
HTH
David
as the finer the paper, the quicker it clogs up. Wet sanding is used a lot on automotive paint jobs as it removes the orange peel and gives that nice, deep polished look. By using water while sanding, it helps the sandpaper from clogging up so fast and also helps lubricate/polish/cool the surface being sanded. I actually sprayed a bit of WD-40 cleaner on my paper when doing it, but I wouldn't advise that.
The lights arent too hard to remove, any $15 dollar manual from an automotive parts store can show you how. There maybe steps/pictures already here in the forum's archives or on Install University's site.
The plastic Polish and sand paper can be purchased from most automotive paint supply places and even Pep Boys. Meguiers, 3M and others make the polish.
HTH
David
thanks a lot rocndav 
two last questions, could anyone give an approximate estimate of the time needed for each step or grit of sandpaper
and i just assume that the polish has all the instructions i need on it?
two last questions, could anyone give an approximate estimate of the time needed for each step or grit of sandpaper
and i just assume that the polish has all the instructions i need on it?
You'd probably want to spend 20-30 minutes per grit at least. I spent 30 seconds to a minutes, doing only half of the headlight to see a true before and after. I was amazed how it came out with spending so little time on it.
The plastic polish is just a final polish. you use it as you would polish a car. dab some on a terry cloth towel (or old athletic sock, inside out) and rub away
The plastic polish is just a final polish. you use it as you would polish a car. dab some on a terry cloth towel (or old athletic sock, inside out) and rub away
LS1 Tech Stories
The Best V8 Stories One Small Block at Time
Topdon ONE vs. Artidiag 800 BT2: Which is the Diagnostic Tablet For You?
Pouria Savadkouei
Gas Monkey Built a 6-Wheel Ferrari Testarossa With a Corvette LT4 Engine
Verdad Gallardo
7 Most Reliable High-Performance Engines GM Has Ever Built
Verdad Gallardo
Amazing '71 Camaro Restomod Is Modern Muscle Car Under the Skin
Verdad Gallardo
6 Common C5 Corvette Failures and What's Involved In Repairing Them
Pouria Savadkouei
Retro Modern Bandit Pontiac Trans AM Comes With Burt Reynolds' Autograph
Verdad Gallardo
Top 10 Greatest Cadillac V Series Performance Models Ever, Ranked
Pouria Savadkouei
Top 10 Most Powerful Chevy Trucks Ever Made!
Hennessey's New Supercharged Silverado ZR2 Has 700 HP
Verdad Gallardo
Thread Starter
TECH Fanatic
iTrader: (11)
Joined: Nov 2003
Posts: 1,781
Likes: 0
From: Marysville, WA
The very first post in this sticky thread tells the process I used. More detailed information is provided throughout the thread, please read it all the way through before asking questions that may have already been answered.
12 Second Club
Joined: Feb 2005
Posts: 170
Likes: 0
From: Garland,Tx
THinking of doing this but wanted to ask one thing for you guys that have done this before. Did your headlight before you did this look clearer when you got it wet like when you were washing you car and then as it dried it got hazey?
Last edited by brokez; Aug 21, 2005 at 08:40 PM.
Thread Starter
TECH Fanatic
iTrader: (11)
Joined: Nov 2003
Posts: 1,781
Likes: 0
From: Marysville, WA
Originally Posted by mongoose
is a 3-step system really necessary? will the zaino 1-step plastic polish be as effective? i have some laying around that i never used...
Thread Starter
TECH Fanatic
iTrader: (11)
Joined: Nov 2003
Posts: 1,781
Likes: 0
From: Marysville, WA
I'm not sure, I've never examined that type of headlight. Some manufacturer's use a different coating over the plastic lens to protect it. This coating is too hard to sand/polish, and sanding it can potentially ruin the lens. I'm not sure what type of lenses are on the Grand Am?
I didn't know what was on the Camaro either, but my lenses were soooo bad I just took the chance. Halo's were the backup plan if I ruined them!
I didn't know what was on the Camaro either, but my lenses were soooo bad I just took the chance. Halo's were the backup plan if I ruined them!
damn u got better results than me....but then again i used a polish that i make to polish the lenses, and the polish is made for aluminum so maybe i'll try that stuff u orderd