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Restore DOT Plastic Headlights to
"Like New" Condition (by Gro Harlem)

Applications: Universal Estimated Time: 2 to 3 hours

Are you headlights yellowed, cloudy or just plain look like shit? Years of sun, condensation and exposure to hot and cold weather can change the color or appearance of factory headlights drastically. You will also increase the light output of your factory headlights.

To get rid of all of the weathering, and yellowing you should clean out the inside and outside of the lens. The steps in this how-to tell you how to do both of these, and also clean the inside of the housing itself. Simply cleaning the outside lens is not going to be as effective, but will get rid of some of the yellowing and cloudiness.

Tools/Supplies you will need:

  • Bottle of "Blue Magic" Plastic cleaner ($5)
  • Tube of Black Silicone Sealant($2.50)
  • Roll of paper towels
  • Aluminum Foil
  • Nail Brush
  • Dremel w/polishing bit (optional)
  • Small flat-head screwdriver
  • Larger flat-head screwdriver



Installation Instructions:

1: You will need to remove your headlights to polish them. On Mazda MX3's there are 4 10mm bolts holding it to the body. Two are easily seen from above when you pop the hood. The third is behind the grille and quite easy to spot. The 4th is difficult to remove, but can be removed with a small wrench or ratchet. You have to remove your turn signal housing and reach your arm through the opening and remove the bolt (which should be visible).

For 90-94 Proteges and 323's there are 4 10mm bolts holding the headlight to the body. These bolts are easily removed by removing the front grille, and both corner lights, and should be easily seen once you do this. The whole housing w/bracket comes out as an assembly

Removeing the headlight from the adjustment bracket is up to you. It might be a good idea, as the housings are fragile, especially with age and can easily break apart if you aren't careful.

2: Before you start heating the headlight, remove all 4 of the clips holding the lens to the housing. Also remove any rubber seals attached to the headlight (like on the mx3) or anything else that blocks the lense from seperation

Also don't forget to remove the headlight bulbs themselves...they should pop out with ease.

3: Preheat your oven to 250 degrees

While it is warming up, take a cookie sheet and put some aluminum foil over top of it.

Also, get your screwdrivers ready to use next to the oven, along with some oven mitts or something similar.

You should also wash the headlight housing as your oven mitt will get pretty dirty handling the housing without prepping it

4: Turn the oven OFF and place the headlight on the cookie sheet into the oven. Heat it for 6-7 minutes.

Now remove the headlight and quickly get your smaller screwdriver and start prying the lens away from the housing. BE VERY CAREFUL not to break the housing, it is very brittle and if you force and twist the screwdriver, you will break peices of the "lip" of the housing off. I did this numerous times with my drivers side headlight.

On the MX3 i found the wider rounded-end of the headlight to be the best starting point (the part under the rubber gasket you removed)

After you start prying, use the larger screwdriver to further the gap between the housing. I found it helpful to use a sharp knife or scissors to cut the old silicone while I was stretching it away from the housing.

You may have to repeat the heating process more than once if you find the silicone hard to work with. I had to heat my drivers headlight twice to get it seperated, but once I got the hang of it, my passenger one took no time at all to seperate.

Another thing to note, you should try to get as much of the silicone off as possible as it will make it very difficult to get the lense back on if you leave too much on.

 

5: Once the lens is off, you should clean it with some dish soap, warm water and scrub it with a nail or vegetable brush to get all of the crap off of it so you won't scratch it up when you polish it.

6: Now you can start polishing. For my headlight lens, I polished the underside 2 times, first time using the dremel to get the contours of the beam pattern and the second time just rubbing with a paper towel. If your headlight is VERY yellowed, you should polish it 3 or maybe even 4 times.

As for the top surface of the headlight lens, I polished mine 5 times total which turned out very well. If yours are bad, polish it at least 7 times to get all of the fogginess and yellow out of the lense.

After polishing it, you can wipe all of the polish residue off and put the lense onto the housing to see how it looks. I did this to determine how many times I should polish it.

7: Also, don't neglect the housing! Polishing the chrome inside made a difference for my housing slightly, but I could notice a difference. Don't use too much polish when you do this. I removed the black inside metal bracket that covers the bulb so I wouldn't bend it, it only takes an extra 30 seconds so don't be lazy!

After you polish it, get ALL of the residue off. I used a can of compressed air to blow off the residue and any paper particles from the paper towel.

 

 

8: Before you install the lens back onto the housing you should clean the lens thuroughly with dish soap and the scrub brush in order to get all of the polish residue out of the "DOT" and other numbering lettering on the inside. I scrubbed mine for about 5 minutes to make sure I didn't have any of that crap on there.

Also, you might want to heat up the headlight housing for 4-5 minutes and start removing the old silicone to get the lens back on. I used my smaller flat-head screwdriver to strip the old silicone off of my housing after I re-heated it

9: Now that everything is prepped, open your tube of silicone and cut the squirt-tip so that it is about 2mm in diameter. Spray that crap in the crevice of the housing so there is a decent amount, but be careful not to get any of it on the chrome.

After that, press the lens back onto the housing. Grab the clips and snap them back into place.

Let the housing dry for a few hours (I left mine overnight) and you should be ready to reinstall them!

Your finished!!! You will notice that your beam pattern is more spread out and more defined, and that your headlights seem brighter!