Headlight Restoration - Dans Method

[DMS_Dan]

Howdy Dubbers!!

Some time a go i promised a guide on how to fix oxidised headlights. It had been a while since i needed to do one so when this one came around i made sure i had the camera ready!

This car was a BMW E39 5 series circa 2000 (i think)

Before you start you will need.

1. Masking tape
2. Sandpaper. I recommend the MicroMesh kit. It is what i use due to the grades that it comes with. At the very least get some 1500, 2000 and 2500.

The micromesh kit comes with all these


3. Polish. I use Menzerna which is designed for paint but still works. There is also a very good Duragloss plastic polish available
4. A buffer (rotary, forced rotation or random orbital) Rotary is the most dangerous but fastest. Forced rotation is less dangerous but slower and the random orbital is safe but slowest. You can also use a mothers mini powerball with great success.
5. Buffing pads. At the very least you will need yellow and blue.
6. A flexible sanding block.

So how it happens

1. Soak your sandpaper in a bucket of water for 30 mins.
2. Wash the lights
3. Mask the surrounding areas
You will be left with this

4. Spray some water or clay lube (i use Dodo Born Slippy) on the lights and using a flexible sanding block rub the lights back with the 1500.
You are left with this

5. Repeat the process again and again moving onto a finer paper each time. Before you move to the finer paper make sure that all the marks from the previous step are gone. EG dont move onto 2400 unless the 1800 has removed all the marks from the 1500.
6. This picture is after the 2400


7. This picture is after the 6000


8. Once you have used the 12000 rewash the light and dry it throughly.
9. Polish the light using your chosen polish and the pad. You may need to do this several times to get the sanding marks out. If using menzerna use intensive polish on the yellow pad followed by final finish on the blue pad.
10. remove the tape and clean the light again. You can rewash it or use some alcohol to remove the polish residue.
11. Apply a synthetic seanant with UV inhibitors. I used Zanio Z2 Pro. This stops the problem from re occuring.
12. You will be left with this. Much much better and much much cheaper than replacement lights!


As always of you have any questions dont hesitate to ask!

Dan

[AusScare]

Fantastic idea, must transform the look of the front end as well.

Nice work.

[Mrk_Mickey]

^^^ Indeed, Dan did you happen to get any before and after shots of the whole front end? I'm keen to see how much of a difference it makes

[Dyldo]

hi Dan

I can't find the Micromesh 9-grade kits (or any kits) on your website.... do you sell them?

[DMS_Dan]

hi Dan

I can't find the Micromesh 9-grade kits (or any kits) on your website.... do you sell them?

Hi Dyldo,

I dont sell anything. I got mine from www.thesandpaperman.com.au

Dan

[carcareproducts]

Hey Dan,

Great write up and good explanation

Mines a 2002 model so I'll book you in for later this year!

Cheers,
Mike

[GoLfMan]

great write up
stickied!

[VW VR6]

Very nice write up...
Well done.

[Dyldo]

With the Micro-Mesh kit, are they to be thrown away after the headlights are done? or can they be re-used a number of times?

If they can be re-used, is there a specific way to care for them such as wrapping them up in glad-wrap or something?

[Mrk_Mickey]

With the Micro-Mesh kit, are they to be thrown away after the headlights are done? or can they be re-used a number of times?

If they can be re-used, is there a specific way to care for them such as wrapping them up in glad-wrap or something?

If it were me, I'd just let them dry and stack them together and leave them in a zip lock bag in my toolkit! They're waterproof wetsanding paper sheets so they should last as least a few goes!