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.http://986forum.com/forums/uploads02/lens1667490857.jpghttp://986forum.com/forums/uploads02...1667490891.jpg

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 just noted that the inner lenses on my 2000 S project are burned, so am following this with interest.

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.

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.

I went ahead and put it back together. Not too bad. Here's the one I repaired next to the scortched one. http://986forum.com/forums/uploads02...1667762203.jpg

Interesting... where did you get the replacement lense?

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.

Would you mind revealng the part number? Thank you! :cheers:

Sure: 025575-PL

$10

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.

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.

I'm not too keen on this "fix".
But, what is the exact diameter of the lenses and reflector? Maybe a pair of DOT approveed sealed beam bulps can be found in the correct dimension and mounted where the whole reflector/lens assembly sits?

R

Did you ever try calling all of the auto wrecking companies in your area. In the larger metro areas (I'm in the Chicago area) there are usually lots of them. The ones near me know their inventory and will usually let me walk the property, remove what I want and bring it up to the counter to "negotiate" a price.

Just a thought.

mine has drivers side discoloring
 

i've got new bulbs to put in and i've been wondering about that issue, napa night vision bulbs BPH7NVB2-N hope they dont make it worse

Sealed beams? Better off duct taping a flashlight to the fender.

As pilot4fn noted, you can also get these from Sierra Madre Collection, rather than using a generic part.

headlight-lens-set-986-996-99-05-p32132

A while back I looked into LED projector bulb replacements, but I don't have the burnt lens problem and didn't want to bake the housings open. It's been a while and I don't have the pages saved, but something like this-

https://www.amazon.com/BraveWAY-Headlight-Cut-Off-Projector-Replacement/dp/B0C28C2VKS/ref=sr_1_5?crid=2GI93E72OOMDT&keywords=h7+led+mini +projector+headlight+bulb&qid=1697591190&sprefix=h 7+mini+pr%2Caps%2C183&sr=8-5

The light pattern is controlled by the lens at the front of the assembly so the lack of the internal lens wouldn't matter. Not sure about the quality of anything on Amazon, but I think there are some good ones out there.