[atxtouareg]

This weekend I decided to tackle the cleaning of my lenses. While I had them apart I painted the housings. This isn't quite a DIY, but my experience with the project.

Tools used:

1: Dremel multi tool with reinforced cut-off wheels
2.Sandpaper (Grits 220, 400, 600, 800, 1500)
3.Rubbing Compound and Polishing Compound with wool/foam pad (Not pictured)
4.Duplicolor shadowchrome paint / Black and silver paint as well
5. Bullydog Adhesion promoter
6. 3M Window Weld
7. Various clamps, flat head screwdrivers, prying tools, etc.

Heres the headlight in it's tired OEM form. My previous attempts at keeping them clear have failed. The issue is in the plastic and alot of sanding and polishing was needed to clean them up.

First thing I did was cut into the housing where the lenses sits into. I took note from another joey mod thread about cutting the "c" into an "L". Here's the best picture I have that shows the cut.

After I cut around the entire housing, I put the headlight in the oven for about 5-7 min at 250*. Once warmed, I pulled it out and began removing the plastic and rubber holding the lens in place.

It took a few trips to the oven, but in about 20 mins I had the lens off.

Look at the how clouded and destroyed the lens was. (Lens on left side of image)

So now I decided to paint the chrome surround. Using a combination of the duplicolor shadowchrome and black paint I achieved a rather unique design over the standard blackout.

I don't have any pictures of the sanding, rubbing and polishing of the lens. I will say that it took time...alot of time to clean them up but it can be done. The micro cracking I found was in fact on the front of the lens and not internal like previously thought. I kept sanding until the entire UV coating was gone. I held it up to the light to ensure proper leveling. Then I raised the grit level and then started with the rubbing compound on a drill mounted wool pad. After many repetitions, I achieved what I was after. CLARITY.

I have noticed the projector cut off is more pronounced than before. The lenses no longer scatters the light around.

I am very happy with the results. It is a lot of work, but with no support from the aftermarket community we have to work with what we have.

 

[catalystgod]

looks good.

 

[tballoun1]

Mine need some attention too...
Well done

 

[English]

so you have to cut the headlight open? I haven't removed my headlights to check but when i removed the lenses on an old Audi i had i just heated them with a heat gun, slowly going back and forth......the VW must be different.

I do like how the paint turned out though, very well done sir

 

[snooreg]

That looks beautiful! It's surprising how much difference the lenses make.

 

[PutterMcGavin]

Looks great!

Any more pictures from different angles? I'm thinking about tackling this with my black Treg as well.

 

[magrider]

What did you use to seal the headlight back up?

 

[atxtouareg]

You do have to cut them open to do the joey mod but its not a drastic cut, there's a "C" channel that holds the lens in place with the rubber sealant. If you cut the top part of the "C" channel, you are left with an "L" shaped channel. This just aids in the removal of the lenses without putting too much stress on the plastic. If you are just wanting to revive the clear lens, you dont need to take them apart.

Here are some pics once I applied a UV coating to the lenses.

 

[atxtouareg]

What did you use to seal the headlight back up?

3M Window Weld. The same stuff used to apply windshields.