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Old 11-03-2022, 08:56 AM   #1
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Headlight Inner Lens Repair Idea

One of my headlights is toasted. A search for replacement lenses came up pretty much empty, except for some half lenses in Europe. I decideded to attempt to repair the lens by cutting out the scortched section and replacing it with a smaller circular lens. I didn't want to experiment on mine so I bought the cheapest used headlight I could find on ebay and went to work. Originally I thought I could find some lenticular polycarbonate sheet but struck out there too.

The headlight lens I removed from the ebay unit was scortched far worse than my original. So much that I couldn't cover it with the roughly 5-inch circular lens. I ended out cutting way outside the circle and tried to piece meal some material from the cut up lens.

Anyway, here's what I ended up with.

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Old 11-03-2022, 12:59 PM   #2
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I purchased new lenses to my 2001 from Sierra Madre Collection (US firm):
https://************************************************** **********************************.com/Headlight-Lens-Set-986-996-99-05-p32132.html

oh-well, that was bloked, but this is their part number: SMC.631.05
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Old 11-04-2022, 04:47 AM   #3
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I just noted that the inner lenses on my 2000 S project are burned, so am following this with interest.
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Old 11-04-2022, 12:23 PM   #4
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Originally Posted by pilot4fn View Post
I purchased new lenses to my 2001 from Sierra Madre Collection (US firm):
https://************************************************** **********************************.com/Headlight-Lens-Set-986-996-99-05-p32132.html

oh-well, that was bloked, but this is their part number: SMC.631.05
I've come across those in my search. I'm guessing the attachment is the same as the standard lens, its just missing most of the lower (high beam) area. I might just consider getting them. Obviously way overpriced but then the alternative is $1000 for a new headlight, it might start to be attractive.
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Old 11-04-2022, 10:34 PM   #5
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Theses seem to be the same - more product pictues on the website:

https://www.rosepassion.com/de/p560434-austauschsatz-innere-scheinwerferlinse-boxster-986-996-98-2001-paarweise-paar-P560434

Don't think that they solve your problem.
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Old 11-06-2022, 11:17 AM   #6
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I went ahead and put it back together. Not too bad. Here's the one I repaired next to the scortched one.
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Old 11-06-2022, 06:41 PM   #7
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Interesting... where did you get the replacement lense?
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Old 11-07-2022, 11:00 AM   #8
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Its a moped headlight lens from scooterwest.
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Old 11-07-2022, 05:11 PM   #9
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Quote:
Originally Posted by Wret View Post
Its a moped headlight lens from scooterwest.
Cool, great lateral thinking! Keep us up to date on how it works and what the focus is like.
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1987 924S 5-speed (Sold) - Blue 2000 Boxster 5 spd (Sold)
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Old 11-08-2022, 03:18 PM   #10
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Quote:
Originally Posted by Wret View Post
Its a moped headlight lens from scooterwest.
Would you mind revealng the part number? Thank you!
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Old 11-09-2022, 07:46 AM   #11
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Would you mind revealng the part number? Thank you!
Sure: 025575-PL

$10
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Old 11-09-2022, 07:56 AM   #12
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Originally Posted by elgyqc View Post
Cool, great lateral thinking! Keep us up to date on how it works and what the focus is like.
Much impoved over the brown spot of the old one. Focus / spread seems good. If I get a chance I'll see if I can a pic against the garage door.

I am using with LED H7 replacement bulbs. Not entirely happy with the light intensity and using them for anything other than low beams is problematic.

Overall I am happy with the repair. It is not noticably different than the non-repaired headlight. This one was intended to be practice prior to hacking into my other one and but it's good enough that I will likely leave it in and shelve my other as a spare.
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Old 11-09-2022, 06:12 PM   #13
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Have you sealed it back up? I would love to see the difference between your repair and simply removing the inner lens completely.
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Old 11-10-2022, 06:46 AM   #14
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Have you sealed it back up? I would love to see the difference between your repair and simply removing the inner lens completely.
Yeah, it didn't occur to me to test the light pattern without the lens but I've heard of others doing that. Maybe I'll pull the other one apart when I get time and compare repaired lens vs. no lens.

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