04-01-2014, 09:14 PM
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#1
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Custom User Title Here
Join Date: Mar 2012
Location: Ft. Leonard Wood
Posts: 6,164
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Scary Stuff!!!!
...taking sandpaper to the inside of the outer lens.
The inside of the lens was badly gouged and had some scratches and the only other option was replacement, so I went for it.
Wet sanding, 500 grit.
Wet 1000 grit.
Wet 1500 grit.
Wet 2000 grit.
Wet 2500 grit.
Foam bonnet and plastic polish.
Wash with warm water, Dawn dish soap, and clean fingertips only! No cloths or sponges.
Shake water off.
Flush with 90% or better denatured alcohol to rinse remaining water drops off.
Use canned compressed air to remove any lingering alcohol.
Fin...
Easily one of the scariest things I've done 
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Last edited by particlewave; 04-02-2014 at 09:29 AM.
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04-01-2014, 11:04 PM
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#2
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DIY extremist
Join Date: Jul 2011
Location: Brooklyn
Posts: 348
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wow. I wouldn't have ever attacked with 500 grit!
Was there a nasty scratch?
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"Betty" -- 2000 Boxster S, Triple Black, loaded except PSM (sold to a good home)
"Veronica" -- 2008 Boxster S, Arctic Silver on Blue
"Maleficent" -- 2007 Cayman S, Red and Black, TPC Turbo 3.6L 460 RWHP, H&R RSS Coilover / TPC stage 2 suspension
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04-01-2014, 11:13 PM
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#3
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Custom User Title Here
Join Date: Mar 2012
Location: Ft. Leonard Wood
Posts: 6,164
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A gouge about 0.5-1mm deep!
Several, actually.
The headlight had suffered significant internal damage. The lens was only a small part of it.
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Last edited by particlewave; 04-01-2014 at 11:21 PM.
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04-02-2014, 01:03 AM
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#4
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Registered User
Join Date: Jan 2014
Location: scotland
Posts: 24
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nice job mate ,its one of those jobs that you never know the outcome till you start ,then after you've made the first rubdown you then have to keep going , no stopping half way through ,well done on a gr8 result
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04-02-2014, 02:40 AM
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#5
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Registered User
Join Date: Oct 2012
Location: Cincinnati, Ohio
Posts: 373
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Charles,
Looks great!
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04-02-2014, 05:51 AM
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#6
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Registered User
Join Date: Apr 2012
Location: Riverside, CA
Posts: 1,665
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Nice job.
What grit did you finish up with, or did you use 500 all the way through?
I wonder how the inside of a lens gets messed up like that? Car wreck?
__________________
"It broke because it wants to be Upgraded  "
2012 Porsche Performance Driving School - SanDiego region
2001 Boxster S, Top Speed muffler, (Fred's) Mini Morimotto Projectors, Tarret UDP,
Short Shifter, Touch Screen Dual Din Radio, 03 4 Bow glass Top (DD & Auto-X since May 17,2012)
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04-02-2014, 08:12 AM
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#7
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Registered User
Join Date: Jun 2012
Location: Bedford, TX
Posts: 2,739
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Nice work, you are the master 
__________________
______________________________________________
2001 Boxster S Lapis Blue
TS Cat Bypass Pipes and exhaust
iPad Mini Dash Install
DEPO Tail Lights
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04-02-2014, 08:26 AM
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#8
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Custom User Title Here
Join Date: Mar 2012
Location: Ft. Leonard Wood
Posts: 6,164
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I've been buying wrecked or damaged headlights on eBay for parts.
This means I can use damaged lenses now, too
I finished up with 2500 grit, then polishing compound, then straight polish.
Afterward, as I posted, the polish had to be washed off, but any type of cloth will just scratch it again, hence the warm water, soap, and fingertips only. Using alcohol and compressed air to flush out the water dries it with 0 water spots and no touching
Thanks for the encouragement guys! 
It was tough setting that sandpaper down for the first time...
__________________
https://youtube.com/@UnwindTimeVintageWatchMuseum
Last edited by particlewave; 04-02-2014 at 08:32 AM.
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04-02-2014, 09:14 AM
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#9
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Registered User
Join Date: Jun 2012
Location: Bedford, TX
Posts: 2,739
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Are you going to start selling completed units? If not, you need to. When you compare these to buying a set of stock Litronics, there is no comparison for those of us with the OEM halogens IMO.
__________________
______________________________________________
2001 Boxster S Lapis Blue
TS Cat Bypass Pipes and exhaust
iPad Mini Dash Install
DEPO Tail Lights
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04-02-2014, 09:28 AM
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#10
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Custom User Title Here
Join Date: Mar 2012
Location: Ft. Leonard Wood
Posts: 6,164
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That's the plan, Bruce.
A lot of people want the projectors, but can't go the 2-3 weeks without headlights, so I thought I'd convert a few pairs for those who just want the whole unit
__________________
https://youtube.com/@UnwindTimeVintageWatchMuseum
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04-02-2014, 09:47 AM
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#11
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Registered User
Join Date: Jun 2012
Location: Bedford, TX
Posts: 2,739
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Quote:
Originally Posted by particlewave
That's the plan, Bruce.
A lot of people want the projectors, but can't go the 2-3 weeks without headlights, so I thought I'd convert a few pairs for those who just want the whole unit |
I think you are going to be very busy
__________________
______________________________________________
2001 Boxster S Lapis Blue
TS Cat Bypass Pipes and exhaust
iPad Mini Dash Install
DEPO Tail Lights
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04-02-2014, 09:48 AM
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#12
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Custom User Title Here
Join Date: Mar 2012
Location: Ft. Leonard Wood
Posts: 6,164
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I already am!!!
Ok, I need to get off of here and get to work 
__________________
https://youtube.com/@UnwindTimeVintageWatchMuseum
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04-02-2014, 10:02 AM
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#13
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Registered User
Join Date: Sep 2013
Location: Montreal, QC. (currently expat to Shanghai)
Posts: 3,249
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You wouldn't ship Int'l by any chance? I've been playing the purist porsche type guy and hidden my crush for the angel eyes for too long
I have a set here that could do well in a garbage can. Lenses were off for a few months and since a few people played with them. They are completely wrecked. I'll try your technique on a hot day here and see if I can rescue those.
If this works I'll report back to confirm that you have found the perfect combination of abrasive grits for lenses restoration!
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'97 Boxster base model 2.5L, Guards Red/Tan leather, with a new but old Alpine am/fm radio.
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04-02-2014, 10:12 AM
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#14
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Custom User Title Here
Join Date: Mar 2012
Location: Ft. Leonard Wood
Posts: 6,164
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Fred, if you only have light to moderate scratches, a foam bonnet and polish will do the trick
Maybe some compound first if they're stubborn.
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https://youtube.com/@UnwindTimeVintageWatchMuseum
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04-02-2014, 10:23 AM
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#15
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Registered User
Join Date: Jun 2012
Location: Bedford, TX
Posts: 2,739
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Quote:
Originally Posted by particlewave
I already am!!!
Ok, I need to get off of here and get to work |
I should have said busier
__________________
______________________________________________
2001 Boxster S Lapis Blue
TS Cat Bypass Pipes and exhaust
iPad Mini Dash Install
DEPO Tail Lights
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04-02-2014, 11:10 AM
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#16
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Registered User
Join Date: Apr 2012
Location: Riverside, CA
Posts: 1,665
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Particle, you should apply a "Core Charge" model so when they get their new set installed and send in their old set they get the core charge back, and then you don't have to go looking for new headlamps on ebay and in theory the quality of the product should remain high because you will eventually be using other folks good lenses instead of ones from ebay that may be a little sketchy sometimes. You could also justifiably raise the price a bit as well if necessary.
__________________
"It broke because it wants to be Upgraded "
2012 Porsche Performance Driving School - SanDiego region
2001 Boxster S, Top Speed muffler, (Fred's) Mini Morimotto Projectors, Tarret UDP,
Short Shifter, Touch Screen Dual Din Radio, 03 4 Bow glass Top (DD & Auto-X since May 17,2012)
Last edited by jb92563; 04-02-2014 at 11:16 AM.
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04-02-2014, 11:13 AM
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#17
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Registered User
Join Date: Jun 2012
Location: Bedford, TX
Posts: 2,739
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Quote:
Originally Posted by jb92563
Particle, you should apply a "Core Charge" model so when they get their new set installed and send in their old set they get the core charge back, and then you don't have to go looking for new headlamps on ebay.
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The trouble would be the "core". Some would be in excellent shape and some, well, you get the idea.
__________________
______________________________________________
2001 Boxster S Lapis Blue
TS Cat Bypass Pipes and exhaust
iPad Mini Dash Install
DEPO Tail Lights
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04-02-2014, 11:17 AM
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#18
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Registered User
Join Date: Sep 2013
Location: Montreal, QC. (currently expat to Shanghai)
Posts: 3,249
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Quote:
Originally Posted by BruceH
The trouble would be the "core". Some would be in excellent shape and some, well, you get the idea.
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Bruce, check again, the guy can bring them back from the dead almost.
Got ya now
__________________
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'97 Boxster base model 2.5L, Guards Red/Tan leather, with a new but old Alpine am/fm radio.
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04-02-2014, 11:57 AM
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#19
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Registered User
Join Date: Jan 2014
Location: Albuquerque, NM, USA
Posts: 743
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How does inside of lens get scratched?
Seems mostly unlikely.
My Litronic lenses are crazed. They look perfect until you turn them on. I assume this isn't reparable.
__________________
Kent Christensen
Albuquerque
2001 Boxster
2007 GL320 CDI, 2010 CL550
2 BMW motorcycles
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04-02-2014, 12:49 PM
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#20
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Custom User Title Here
Join Date: Mar 2012
Location: Ft. Leonard Wood
Posts: 6,164
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Quote:
Originally Posted by lkchris
How does inside of lens get scratched?
Seems mostly unlikely.
My Litronic lenses are crazed. They look perfect until you turn them on. I assume this isn't reparable.
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Car accidents, user accidents, etc.
Anything that causes pieces to float around inside.
One problem I've seen is people touching or trying to wash the inside of the lens during retrofit. This causes many fine scratches that can be seen extremely well with the headlights on.
__________________
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2001 Boxster S
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