Porsche Headlight Retrofit [from CAD, prototyping to finish)

[particlewave]

Originally Posted by Nine8Six

Hi Richard

I didn't see the before and after but I can tell from your tone that you are very happy with what Chales did to them. I bet he added some UV protective coating to them as well. You couldn't have find better guy in the whole of the USA to restore those.

I'm actually still quite the amateur at lens restoration. The inside of the lens is no problem because there's no coating and I can polish them quite easily. However, the outer lens has the UV coating which is very hard to get through. I have yet to find a method of removing the UV layer without causing deep scratches that take hours to wet sand out.

I appreciate the compliments, but I still have a long way to go. The only reason I did Richards was because they were in such bad shape that I could do no wrong.
I'll keep at it, though

Here's a before shot of Richards. I hope you don't mind.

[nieuwhzn]

Originally Posted by particlewave

I'm actually still quite the amateur at lens restoration. The inside of the lens is no problem because there's no coating and I can polish them quite easily. However, the outer lens has the UV coating which is very hard to get through. I have yet to find a method of removing the UV layer without causing deep scratches that take hours to wet sand out.

I appreciate the compliments, but I still have a long way to go. The only reason I did Richards was because they were in such bad shape that I could do no wrong.

My lenses were almost as bad as Richard's. Followed Fred's advice. Wet sand with 1200 grit until no yellow stuff comes off anymore. I didn't have any finer grit sand paper lying around, but rubbing two pieces of 1200 grit together takes their edge off enough to mimic a finer grit. Sanded with those until I didn't see any deep scratches anymore. Then used the step pads of a Turtle Wax Headlight Restorer Kit for a while. Finally used the polishing stuff that comes with that kit on a buffer with modest speed. Used spare amounts of polisher and just kept at it until happy with the result. The whole process is about 2 to 3 hours per headlight.

Btw, I see that Richard's rubber seals are as much turned into mush as mine. Any way to fix this?

Bbtw, what do you use for UV protection?

[Nine8Six]

Originally Posted by nieuwhzn

Btw, I see that Richard's rubber seals are as much turned into mush as mine. Any way to fix this?

I've retrofitted a Carrera a few months ago (3~4months) and use the below high density foam held by a few drops of rtv silicon. Still looking as new today. Not a perfect seal 'as rubber would do' but visually it is the same. Looks 100x times better than nothing at all or the old melted rubber anyway.

Not tested. I have no idea if this HD foam material will last "years" under heavy UV and sun heat. It is however definitely good to use as a quick replacement until you find a donor/oem rubber seal.

Everywhere on ebay in many sizes... $1 type item. DIY fun

[particlewave]

Originally Posted by nieuwhzn

My lenses were almost as bad as Richard's. Followed Fred's advice. Wet sand with 1200 grit until no yellow stuff comes off anymore. I didn't have any finer grit sand paper lying around, but rubbing two pieces of 1200 grit together takes their edge off enough to mimic a finer grit. Sanded with those until I didn't see any deep scratches anymore. Then used the step pads of a Turtle Wax Headlight Restorer Kit for a while. Finally used the polishing stuff that comes with that kit on a buffer with modest speed. Used spare amounts of polisher and just kept at it until happy with the result. The whole process is about 2 to 3 hours per headlight.

Btw, I see that Richard's rubber seals are as much turned into mush as mine. Any way to fix this?

Bbtw, what do you use for UV protection?

Opti-lens is good stuff...any clear coat with a good UV rating is better than nothing, though.