Here a DIY on polishing our lenses I found on bimmerfest for e 46's



DIY: Headlight Lens Restoration / Polish
I have been noticing that my HID headlights don't seem to be as bright these days on my 2003 E46 sedan.

I finally had a good look at them and noticed that both of them, but the left in particular, had developed a "frosted" effect from road grime, sand, and very small impact marks.

I looked in www.realoem.com for the parts to see if I could just get new lenses, but when I checked a typical supplier (autohausaz.com) with the part number, the individual lenses were not available. And anyway the lens listed for $42, each, under the parts list on realoem.

So I stopped by Autozone and picked up a 3M Headlight Restoration kit for $16.99:

- Disc Pad Holder
- 6 x 500 grit pads
- 4 x 800 grit pads
- 1 x 3000 grit Trizact pad
- 1 x buffing pad
- 1 x packet of polishing compound

I supplied my 0-1600 rpm drill, masking tape and water (spray.)

I basically followed the process in the instructions. Took me about an hour and a half:

1) clean the lens
2) wet sand with 500 grit pads
3) wash lens
5) wet finish with 800 grit pads
6) wash lens
7) wet polish with Trizact pad
8) wash lens
9) polish with lens polish
10) wash lens

Things I would have done differently next time:

- Obtain an old sheet or similar from Mrs. Wingspan and drape over engine compartment. The slurry gets thrown pretty much everywhere if you are not careful.
- Spend more time on the 500 grit step.
- Spin up the drill to 1600 rpm and use the rpm lock. I was controlling it by hand initially, this was tiring.

The net result is pretty good. Its not perfect, but the haze / cloudiness is completely gone. It does take a little intestinal fortitude to attack your clear plastic headlights with an abrasive drill pad () but I got over that.

I used most of the pads, but only about 1/4 of the packet of polishing compound.

Pictures are:

1) Restoration kit components

2) Left hand lens, at start of process

3) Typical "slurry" effect, this one after the 800 grit pad

4) Final appearance, much improved.

Overall, I am pleased to get a good result for the time and the cost of the kit.

I tried to link some photos of the process.

http://www.bimmerfest.com/forums/att...9&d=1211060994
http://www.bimmerfest.com/forums/att...8&d=1211060959
http://www.bimmerfest.com/forums/att...7&d=1211060921
http://www.bimmerfest.com/forums/att...6&d=1211060882