This is my first instructable, so I hope all goes well.
Headlights begin to fade over time, and there's no way around it. As your headlights fade, the amount of light that makes it out of the headlight becomes less, and before you know it, driving at night becomes difficult, but more importantly, dangerous. This is due to oxidation on the lens. Once oxidation begins to take place, it quickly degrades the headlight lens, because polycarbonate is a porous material. Wet sanding (what we will be doing) helps to remove this oxidation and restore your headlights to a safer condition.
I have been restoring headlights now (mine and a few friends and family) for quite some time, and I feel that the knowledge should be passed to others. So without further adieu, let's get started.
What you will need:
-Sand Paper with values: 800, 1000, and 2000 grit.
-A Small Towel, Rag, or Microfiber Cloth
-3M Rubbing Compund
-Automotive Masking tape
-A Drill (corded or cordless)
-Compound Pad (Wool pad works as well), with drill adapter
-A Spray Bottle with Water
-A Small Measuring Cup (one you don't use for food)
-Minwax's Helmsman Spar Urethane : Clear Gloss.You need this specific kind.
-Odorless Mineral Spirits
-2 to 3 Hours put aside (depending on your attention to detail)
First step is preparation. We want to get everything ready. Remember, this will take some time, so you might wanna get some music out and a couple of speakers to help pass the time. This is also the time you need to take to fill your spray bottle with water. Hint: you can add a little soap to the water. This helps keep the headlight lubricated while using less water, but you don't need any more than a few drops.
Now, we need to tape up the area around the headlights. This is the first and most important step of the whole process. You want to make sure to tape up any and all paint surrounding the headlights. You will be spending quite some time on your headlights. After all your hard work work is done, you don't want to have to fix the paint as well!
Next, after all the taping has finished, we can begin the fun.
-Cut your sand paper sheets into fourths (I found mine at Walmart for about $3 and change per pack. Each pack contains 5 sheets.)
-Get out your 1/4 sheet of 800 grit sandpaper, and spray it with the water bottle. Place the sand paper on the headlight (it will stick by itself) and continue to spray the whole headlight until the whole headlight is wet.
-Slowly start sanding the headlight making sure to spray water while you sand. Water isn't needed, but helps to make the paper last longer and make it easier. Make sure to sand all the edges and all the corners. Do this for both headlights, making sure not to reuse the sandpaper from the opposite headlight. 1-1/4 piece of sandpaper per headlight.
Helpful Tip: Sand in one direction. This makes it easier for you to check and see that your lines are consistent and that you have sanded the headlight evenly. It also helps to see anything you might have missed.
-Continue sanding until you can see a uniform surface of 800 grit scratches (where sanding in one direction helps). Wiping the surface with a towel or shop towel helps to check. When you have removed all the oxidation, and there is a uniform finish, continue on to the next step.