FWD Tech Guides '95-'07 Guides/How-To information for FWD Montes 1995-2007

Repair Guide: Composite Headlight Repair!

Old 11-20-2005, 11:18 PM
Thread Starter
Join Date: Oct 2004
Location: Cherry Hill, NJ
Posts: 226
Default Composite Headlight Repair!

Having problems with your Composite Healights not being clear due to rock chips in the lense?
here is the fix!

You need grits 320,600,800, and 1500 of Wetodry sandpaper, Mother's metal polish, a rag, Plastic polish, and a buffing wheel (I used a plug-in Black&Decker 7" 2 speed, 3/4 HP buffer).

Start off by removing the entire headlight housing from the car. Begin wetsanding the surface with the 320 grit and KEEP IT WET. Take your time and make sure you sand equally over all of the lense. Keep at it with the 320 until the rockchips are gone. Next, move on to wetsanding with the 600 grit, then to 800, and 1500. I took at least 7-10 minutes with each grit for best results. Now, the lense should look really fogged up and way worse than when you started. This is normal!

Take a cotton rag and use it to rub metal polish across the lense. Begin buffing it by hand using the rag. Be generous with the metal polish and put some muscle into it. Take at least 10 minutes with this stage.

Now the lense should look clear, but no very glossy. Take another rag and use it to smooth plastic polish over the surface of the lense. Now use the powered buffing wheel to buff the lense until all the polish is gone and the lense is looking glossier. With an amazing 3/4 Horsepower-powered wheel, I had to secure the headlight housing between my feet. Do this 3 or 4 times.

If you completed all of the above the headlight lense should look as good as new. Stick the housing back in, switch on your lights, and be amazed.. It looks clean!
Old 09-22-2009, 08:43 PM
Join Date: Jul 2009
Posts: 26

Great Info! I heard you can polish out those lenses, I was just going to get new aftermarket assemblies, but Im going to try your idea first. What brand Polish did you use? Please post the brands you used so I can expect the same or close results. Thanks for the Great Post!
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