im resurfacing the headlights on my ZJ... theyre actually quite yellow, i doubt theyll pass inspection when it gets inspected soon

so anyway.. i was using a dremel tool with a buffing wheel to polish the headlights.. and it was working beautifully.. however, the polishing compound filled in some gouges in the headlight lense, making them noticable... i need to repair these gouges

my thought is to sand out the gouged areas, degrease, and fill with clear two part epoxy... scrape off the excess, then when its hardened go over it with a palm sander and 1000, then 2000 grit wet sandpaper to smoth and polish it all up

does this technique of filling it in with clear two part epoxy sound like a good idea?.. or does someone else have a better solution short of replacing the headlights?

 

I got brand new housings from www.rockauto.com for less than fifty bucks shipped to my door. They even come with new bulbs.

 

blue magic lens cleaner cost around 5 buck 2.000 grit wet sand paper follow the directions your done

 

cleaning the lenses themselves isnt an issue.. but the gouges in them is what i need to fix.. i think some clear two part epoxy to fill them in would work well, has anyone tried it?

 

You can try a lot of different things with no success and money spent, or actually fix the problem with new housings as stated in post #2.

 

I feel this would be just like trying to polish plexiglass. If you did fill the gouges with clear epoxy, once you sand them down, I feel like they will just turn into giant white scratch marks and then you'll have weird whiteish looking blotches in your clear headilght. I'm with everyone else...new housings, or some better ones from a boneyerd.

 

no, headlight lenses polish up nicely... they do start out with white scratches but you have to go finer and finer in grit.. and use it wet...

i used a polishing compound with a dremel tool and took off about half the yellowing and cloudiness in less than 5 minutes which is when i discovered the chips.. wet sandpaper would work fine, thousands have done it.. my question was relating more to the clear two part epoxy to fill those in.. dries pretty clear and should remain clear with a fine enough grit, i was wondering if anyones done it yet

 

They will be cloudy and yellow again in no time. Been there and done that, it was well worth the money spent on new housings.