DIY headlight chip repair

In detail: DIY repair of headlight chips from a real master for the site my.housecope.com.

The traffic police inspector wins a "lemon" in the lottery. They ask him:
- How will you spend your money?
- I will buy a crossroads and will work for the soul!

Service "Headlight glass repair" focused on the repair of damaged glass headlights and foglights. The headlights are made of tempered glass. The impact of a stone, as a rule, leads to a through hole, and a large piece of glass breaks off from the inside. Through holes depressurize the headlamp, and besides the fact that the headlamp begins to "sweat", dirt and moisture gets there. The accumulation of dirt and dampness over time will cause the reflector to "cloud" and to peel off the glossy reflective coating, and the headlight will lose brightness.

Headlight glass repair differs from the repair of windshields, primarily by the polymer used, and also purely technologically, since the headlight must be removed in order to carry out repairs on the inner surface of the glass.

On the repaired glass, the tightness is restored and there is no need to replace the headlight unit. On most cars, when it becomes necessary to replace the headlamp glass, you have to purchase the entire headlamp unit, since the glasses that can be replaced are produced for single models.

Today, shock-resistant plastic is installed on the headlights of almost all cars, damage to which is extremely rare. Over time, the outer surface of plastic headlights turns yellow and becomes dull. This defect is removed by polishing.

Impact-resistant, transparent film with a thickness of 0.5 - 1 mm, when glued, repeats the contours of the glass, dampens the impact of an oncoming stone. There were cases when, even when hitting an obstacle, the film kept the glass intact. The film glued to the fog lamp eliminates the effect of "thermal shock", that is, a very heated glass of a small area does not burst when it hits the water.

Video (click to play).

Below is the technology for repairing headlamp glass.

Quite often, damaged optics are difficult to find on the market. You can make an individual request. However, this does not guarantee that it will be implemented. Therefore, it will be very useful to know how to repair car headlights yourself. Before proceeding with this procedure, it is necessary to find out what material the damaged optics are made of. Consider what modern headlights are.

Glass headlights... The most high-quality and efficient specialists are considered to be optics made of glass. It looks beautiful, stylish, transmits light perfectly, is used longer and does not grow cloudy. At the same time, such headlights, in comparison with other analogs, are more fragile, highly susceptible to scratches and cracks. A special film is used to protect the glass. It provides reliable protection against small stones and can be wiped clean without scratching the glass. However, the coating reduces the throughput of the optics by 4-5%, but this can be neglected in order to save money on replacing damaged glass.

Polycarbonate optics is cheaper and more practical. The material is highly resistant to mechanical damage, detergents and temperature extremes. However, there are significant disadvantages:

cloudiness due to ultraviolet rays;
poor resistance to the effects of various alkalis, acids and other corrosive liquids;
relatively short service life.

Acrylic headlights, better known as plexiglass optics. Acrylic, in comparison with polycarbonate, is of higher quality and quickly takes on almost any shape when heated.In this case, after solidification, the degree of transparency decreases by 6-8%. This optics does not grow cloudy, but is more prone to cracking with significant temperature fluctuations.

You will need the following tools to repair your headlights:

hair dryer-soldering iron;
milling machine;
compressor;
injector;
drill;
UV lamp;
pliers;
tweezers;
files;
hacksaw for metal;
sandpaper, circles, or other abrasive material;
Sander;
vernier caliper, ruler, pencil;
plasticine;
heat-resistant vacuum bag;
napkins, protective equipment (gloves, glasses).

Depending on what the damaged optics was made of, we prepare the appropriate material. The best option is shards of previously repaired headlights. If there are none, we prepare a similar plastic. Remember that polycarbonate and acrylic should not be interchanged. If they are welded to each other, then the connection will be fragile. Such optics will not last long, just a few days.

In addition, you will need plexiglass, solvent, scotch tape and special molecular glue. It can be replaced with dichloroethane. To restore the main headlights, it is necessary to prepare plexiglass with a thickness of about 6.0 mm, for sidelights (foglights) or rear lights, a thickness of 4.0-5.0 mm is sufficient.

The body and headlamp are repaired with a hair dryer in the following sequence:

We lay out the fragments in the right order. If some parts are lost or cannot be restored, use spare parts from previously repaired optics.
We heat each piece one by one with a hairdryer and attach it to its place.
We weld the resulting seams on both sides to ensure strength.
The irregularities resulting from welding are first removed with a file, and then with sandpaper.
After that, we carefully grind and polish the restored optics using a felt disc.

Broken pieces of headlights can be glued together using special glue. The repair procedure is similar to the above sequence. If you do not have the necessary parts, you can make them yourself from plexiglass. All seams must be treated with hardener on both sides without fail.

Sometimes the glued headlights may not match the shape of the cap. In this case, a fit is made using a technical hair dryer.

In case of damage to glass optics and the impossibility of replacing with a new one, you can make a similar headlight from plexiglass:

Preparing the template. We put the destroyed optics in parts, replace the lost elements with ordinary plasticine. Then we make a plaster matrix.
We cut a workpiece of the required size from plexiglass.
On tracing paper we draw a template for the internal drawing of the glass with a caliper.
Using a milling machine on a plexiglass workpiece, we reproduce the optics pattern with maximum accuracy.
After that we put plexiglass on a gypsum matrix and pack it in a heat-resistant vacuum bag.
We heat the resulting package until the plexiglass is completely softened and, with the help of a compressor, give it the shape of a gypsum matrix.

It should be noted that this procedure is rather complicated and time consuming. It is difficult to cope with it without the necessary skills and special equipment. Therefore, it is easier to resort to the services of specialists.

The rear lights are repaired in a similar manner. First, the parts of the destroyed optics are laid out on the table. Then, in the required sequence, glue the existing elements with glue.

As a rule, some parts after an accident will be lost or destroyed without the possibility of recovery. Therefore, it is necessary to prepare spare parts from a similar flashlight. First, we prepare a template for the missing element and cut out a piece of the desired shape with the utmost precision. We glue it and prepare the next element in the same way. After bonding, all seams must be carefully sanded and polished.

Visual video on the restoration of rear optics

Headlight cracks are repaired using an adhesive:

We drill the edges of the cracks.
We wash and dry the surface.
Install the injector just above the crack and apply the glue.
After filling the crack with glue, remove the injector and control the absence of air bubbles in the polymer composition.
To make the glue harden faster, you can dry it with an ultraviolet lamp.
After the adhesive has completely dried, we remove the irregularities with a file, and then we grind and polish the lantern.

After filling the cracks, it is recommended to treat the joints with hardener.

We wash the headlight first, then dry it thoroughly. First, rough grinding is performed in several stages with a gradual increase in the grain size of the wheel. It is not recommended to press strongly to avoid overheating of the plastic. The time of one procedure should not exceed 3-4 minutes.

After rough sanding, we proceed to polishing. For this, wipes and polish are used. A small amount of the mixture is applied to a napkin and the surface is manually polished for 6-8 minutes. You can handle plastic headlights using a grinder. In this case, use low speed and avoid overheating of the surface.

It is recommended to polish the optics every 2 years, as well as after repairs and when cracks or chips appear. This procedure takes about 20-30 minutes and is not difficult.

It happens that not all optics for a car can be found on store shelves, so knowledge about headlight repair will never be superfluous.The housing of the headlights or lanterns is repaired by hot-air welding. For these purposes, use a special hair dryer-soldering iron, which is "powered" by the air of the compressor. With the help of a hair dryer, the pieces of the body are returned to their place and attached. Cracked or broken headlights usually have to be repaired, so there may not be enough debris. In this case, spare parts for headlights that have been repaired before will come in handy. Image - DIY headlight chip repair

The seam should be welded both from the outside and from the inside in order to provide the headlights with the necessary strength. Before starting work, you should find out from which plastic the case was made. It could be ABC plastic or polypropylene. If it is ABC plastic, then it can be repaired using the "cold welding" method, but polypropylene can only be welded. Please also note that these materials cannot be combined! If you weld one to the other, you get a very fragile connection.

It happens that the glass in the headlight is completely destroyed, and it is not possible to replace it with a new one. In this case, plexiglass comes to the rescue. Before starting this work, it is necessary to reproduce the shape of the damaged glass. The lost parts at this stage are replaced by plasticine. As a result, a template form should appear on your desk. It is on it that a plaster matrix is made. Then you should cut out a piece of plexiglass of the desired size. Typically, a headlamp requires clear glass up to 6 mm thick, and for sidelights or fog lamps, no more than 5 mm.

Next, you need to take tracing paper and draw the inner drawing of the old glass. To measure everything very accurately, use a caliper. Taking a template, the drawing is reproduced on plexiglass using a milling machine. This allows you to keep the luminous flux almost at the same level and achieve a minimum error.

After the actions taken, both the gypsum matrix and plexiglass are packed in a vacuum heat-resistant bag. The next stage will cause difficulties for many, but it only seems. You should find a special machine or workshop that will allow you to use this device to heat the envelope until the plexiglass softens. At the same time, the compressor helps create a vacuum in the glass. As a result, the outside air pressure gives the glass the shape of gypsum.Note that these steps only help to make the front part of the headlight, but the "sides" are made separately and attached later.

Broken pieces of lantern caps or cracks are sealed with glue, which is called molecular. You can replace it with dichloroethane. If the cap is destroyed all or a significant part of the lantern, then the missing elements will have to be made of the same plexiglass of a suitable color. After everything is glued, the seams are treated with a hardener. Handle the adhesive with care as it can cause burns if it comes into contact with the skin. Image - DIY headlight chip repair

Irregularities in the seams on the headlamp are removed with a file, processed with sandpaper and polished with GOI paste and a felt disc. It will not work to completely eliminate the seams, but they will not affect the quality of light.

If you need to fit the plexiglass to the old cap, then the material is heated with a hairdryer, and the shape is hand-molded. Caps of complex shapes are driven through a vacuum press. The cap is glued to the body of the lantern with a polyurethane sealant.

The new headlights of your car will be stronger than the “native” ones, because they will withstand even a stone blow. The only thing is that this material can become cloudy or scratched. Let's take into account the fact that fog lights can crack due to snow or cold rain, but low temperatures are not terrible for plexiglass.

Good luck with your car headlight repair!

The optics of the machine are subjected to high mechanical stress, which can lead to damage to these elements. The reason may be the car owner's inattention on the road or getting into an accident. It is not difficult to repair the headlight. All it takes is a tool, replacement parts, and a fastener sealant.Headlamp restoration is required in a situation where deformation or damage leads to a deterioration in the light transmittance of the product. As a result, the risk of getting into an accident when driving at night increases. In addition, the yellowed plastic does not have the most presentable appearance.Common headlight defects encountered by car owners include:

The appearance of cracks in the glass.

Violation of tightness at the joints.

Damage to the case and fasteners, scratches and chips.

It is worth noting that headlight repair may be required in the following cases:

The problem may appear if chemical reagents get inside the product. Under the influence of high temperatures, plaque develops on the outer part of the glass, which reduces the transmission capacity of the headlight. In addition, due to the appearance of a foreign "film", the glass may acquire a yellow tint. In this case, it is better to involve professionals to restore the headlight.

Scuffs or chips on the surface of the headlamp can cause fogging. If the deficiency is not eliminated in a timely manner, the mirror layer is disturbed, and the flashlight requires repair. Moisture also has a negative effect, the ingress of which leads to the oxidation of contact compounds. That is why, when fogging up, it is important to quickly fix the problem and get the headlight repaired. To restore tightness, you can use a sealant.

Why does the headlight sweat, and what to do in this case - read here.

In this case, it will be destroyed by the action of "chemistry" and UV rays.

This problem is known to many, if not all car owners. To restore the headlight, the surface is sanded and polished. With the right approach, you can return the glass to its original appearance. It is advisable to repair the lantern only if you have experience, confidence in your abilities and knowledge of the technology for performing work.

Polishing headlights on a car

Together with the restoration, you can do other work - to make tuning the headlights of the car, for example, to apply paint to them. One of the popular options is to apply black paint.

To repair your headlight, do the following:

Prepare the problem area — clean it, wash it and dry it.
Fill the groove with adhesive.Make sure that no bubbles appear during the procedure.
Use a UV lamp to dry the repair area.
Fix the result. To do this, cover the existing crack with hardener.
Polish the restoration area using a sander or emery paper.

In addition to refurbishing the headlight, restoration of the reflector may be required. To do this, do the following:

Peel off the reflector with metallic tape.
Apply chrome paint to the reflector.

Alternatively, when repairing the reflector, you can use metal foil or foil, followed by fixing with a sealant.

Video: How to properly restore the headlights

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The task of the headlamp hydrocorrector is to change the direction of the light beam. If the device fails, then beam alignment becomes unrealistic. That is why the repair of the corrector should be carried out immediately after a breakdown is detected. If recovery is not possible, replace the entire part.To do this, do the following:

Remove the corrector handle.

Unscrew the retaining nut and remove the master cylinder.

Use a screwdriver to unscrew the mount, dismantle the casing, scale and light guide.

Remove the scale illumination lamp in order to dismantle the hydraulic corrector without any problems.

Move the headlights of the machine away from the slave cylinders.

Remove the adjuster assembly.

After installing a new device, return all the elements according to the reverse algorithm.

Video: Repair of the Lada Granta headlight hydrocorrectorIf the video does not show, please refresh the page or ”style =” color: # CC3333 ″> click here

The easiest way to fix defects on plastic is by injection welding. A polypropylene headlamp can be given a second life with conventional welding. Welding seams are used to connect completely broken-off parts of the headlight, since gluing in this case is ineffective. It should be borne in mind that when connecting different materials, it is almost impossible to achieve strength - a headlight welded from plastic of different types will last no more than 1-2 weeks.

Headlight housing repair is a more time-consuming procedure, which is often performed by the method of prosthetics (replacing individual metal parts with new ones). It is better to entrust such work to the specialists of the service center.

Over time, the headlights can turn matte under the constant influence of rising asphalt particles. In addition, optics made of polycarbonate also lose transparency when exposed to sunlight. Typically, polymer headlights are treated with a protective compound, which is important not to damage during the polishing process.Therefore, to restore transparency and remove minor damage, a fine polish should be used; more serious damage can only be repaired after removing the factory protective layer. At the end of the work, it is recommended to cover it with an anti-gravel film.

Plaque on the inside of the headlamp occurs due to the ingress of chemicals during a non-contact car wash. Under the influence of high temperature, it transforms into a cloudy film, which impairs the light transmittance of the optics. The protective film may crack for the same reason. In most cases, it is problematic to completely eliminate these defects due to the difficulty of accessing the inner surface. Without prior experience with this, you can further damage the plastic or mirror layer of your headlight. Therefore, it is better not to risk it and contact a specialized car service.

It often happens, especially after an accident or a large stone hit in the headlight glass, that it is not possible to restore it and requires replacement. To completely replace it, you need to purchase a new glass, this can be done either from us or in any other specialized store, remove the old glass, apply a new layer of sealant and glue the new glass on the headlight. If the sealant on the headlight is thermally collapsible, then this is not so difficult to do, you can use a construction hairdryer, the main thing is to do it carefully and not to overheat the plastic of the headlight. If the sealant on the headlamp is not a thermoplastic, then I am afraid at home and without special skills, it will not be possible to do this and it is better to contact a specialized workshop.

We are a certified installation center for additional equipment. For 7 years we have been engaged in the repair, modernization and tuning of automotive optics of any complexity for cars of different brands and models. We give a 1-year guarantee for the work carried out with us. We specialize in installing / replacing Bi-Led and Xenon lenses, repairing and improving the light of standard headlights. Any work with auto light and backlighting. All equipment is in stock, installation in your presence.

Installation of additional equipment in the Avtoprisma service center is: - keeping the car warranty - 1 year warranty for work - accurate and honest consultation - individual approach - confidence in the quality of work - order fulfillment on time

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Automotive optics is an element on which road safety depends. A burned out light bulb is not the only reason a car headlight fails. The headlight, in addition to the lamp, includes other elements - a washer, a reflector, a diffuser, a hydrocorrector and other elements, the malfunctions of which must be eliminated as soon as possible after detection. What are the reasons for breakdowns of car headlights, how are car headlights repaired and what are the features of repairing certain types? Every car owner should know the answers to these questions.

Restoration of car headlights is required in situations that arise for the following common reasons in practice:

Headlight range control may need to be repaired for three common reasons:

Breakage of the sensor, as a result of which the readings are distorted or completely disappear.
Poor connection, negatively affecting the readings of the device.
The specificity of the car model is a small adjustment angle and other features.

Regardless of the reasons for the breakdown of car headlights, it is necessary to timely perform work on troubleshooting and restoring standard lighting.

Car headlight glass repair is more common than other types of restoration - stones and other debris cause serious damage to the glass at high speed, which degrades the performance of the headlights and reduces the light transmission.

Self-restoration of car headlights is performed in case of cracks and chips. Auto optics repair provides for the following sequential steps:

Thoroughly clean the crack, wash and dry until completely dry.
In the central part of the defect, install an injector for supplying the adhesive mixture.
Fill the crack with adhesive to prevent air bubbles.
Dry the glue after removing the injector (drying is done with a UV lamp).
Cover the sealed defect with hardener to secure the result.
The final stage is polishing with emery or a grinder.

This completes the restoration of the headlights. This is just a small part of the work that an ordinary car enthusiast may face. Refurbishment of the headlamp reflector is often required. For this, the following methods are used:

Pasting a pre-degreased reflector with metallized tape.
Painting of reflectors of headlights with chrome paint. Full restoration of headlamp reflectors using this method occurs 1-2 hours after painting.
Do-it-yourself headlight reflector restoration using metal foil or film. The strips of the film are fixed under the influence of a hair dryer, and the corrugated elements are painted with chrome paint.

Sometimes restoration of the headlamp reflector is impossible due to serious damage - partial or complete melting under the influence of high lamp temperatures. In this case, you can make a reflector yourself or purchase a finished product in a specialized store. It is important to select the model recommended by the manufacturer, and when making your own production, carefully monitor compliance with this compliance.

Repairing a headlight washer often consists in cleaning the mechanism from accumulated dust and dirt - for these purposes, WD-40 or an oil of similar properties is used. You can reduce the likelihood of a washer breakage by using it regularly, preferably at speed.

The headlight hydrocorrector is designed to change the direction of the light beam. Failure of the device limits the ability to adjust, therefore, the headlight hydrocorrector should be repaired immediately after a malfunction is detected. If the headlight range control cannot be repaired, it must be replaced:

Remove the handle of the hydrocorrector and remove the master cylinder, which is secured with a fixing nut (must be unscrewed).
Remove the trim, scale and light guide by unscrewing the elements with a screwdriver.
Remove the scale illumination lamp, which prevents the removal of the corrector.
Disconnect the slave cylinders from the headlights.
Remove the entire hydrocorrector.

Installing a new device is carried out upside-down.

Do-it-yourself headlight repair is made easier when you are dealing with a plastic construction. It is possible to remove external defects by means of heat welding - powerful streams of hot air melt the required part of the structure, after which it is given the desired shape or the split-off part of the headlight is attached. The main rule is that heat welding is performed only between parts made of the same plastic.

Repair of car headlights also includes the restoration of the mount, which suffers especially often in plastic structures. It is not recommended to use the previously indicated welding method for this - the fastening will not last long. The best option is prosthetics, which must be trusted by professional craftsmen in car services, as well as complex repair of car optics.

The headlight, like any part of a car, wears out over time, as evidenced by a less bright and blurred beam. A decrease in the quality of light can be triggered by various reasons. One of them is the deterioration of the reflective properties of the reflector. We will talk about this and how to independently restore the headlamp reflector in this article.

First of all, the violation of the mirror layer occurs due to the physical wear of the reflector. Its service life is not infinite. Even with a careful attitude to the car, it is impossible to avoid temperature changes in the winter. Therefore, the likelihood of encountering this problem cannot be ruled out.

Often the cause of damage to the reflector is a violation of the tightness. Fine particles of dust and moisture enter the interior and cause the reflector to lose its gloss. As a result, the quality of the luminous flux gradually decreases.

Loss of reflective properties can also be caused by the installation of non-standard, higher wattage lamps. The temperature inside the headlamp reaches a critical value, after which a burnt spot forms on the surface of the reflector.

Whatever the reason, the reflector must either be replaced or refurbished. The cost of restoring one reflector in a car repair shop is not less than 1,000 rubles, which is not acceptable for every motorist.Therefore, we propose to consider several simple ways to restore the headlamp reflector with your own hands.

To get to the reflector, the headlight removed from the car must be disassembled. The first option provides for repeated passage of the seam with hot air from a building hair dryer. The second option is to leave the headlamp in the oven at 100 ° C for 20 minutes. After opening, all parts are cleaned of sealant residues, washed without the use of alcohol-containing liquids and dried.

The sealant that holds the headlamp components together begins to deteriorate when exposed to temperatures above 75 ° C.

Let's start with how to restore the reflector on the headlight using tape foil. All you need is metallized tape, bought at a hardware store for about RUB 30. Its adhesive base copes well with high and low temperatures, and the aluminum film is very wear-resistant.

In order to obtain a smooth surface with a minimum of seams after gluing the adhesive tape on the reflector, first pieces of the most suitable shape are formed from several strips. Then remove the protective film and carefully stick it on. The whole procedure takes about half an hour.

The surface must be degreased immediately before gluing.

Advantages of the method: durability, low cost, ease of implementation.

Disadvantages: when gluing, irregularities and seams remain, which impair the properties of the reflector.

Aluminum foil is highly reflective, which makes it suitable for refurbishing headlamp reflectors. You will also need some epoxy. To maintain a perfectly smooth surface of the foil, the entire pattern is made from plain paper. Then the parts are duplicated from an aluminum sheet, a thin layer of resin is applied to the reflector and glued, removing excess resin.

Advantages: withstands any temperature fluctuations.

Disadvantages: being between the metal foil and the plastic base, the epoxy glue is devoid of air and takes a very long time to dry. It is almost impossible to remove dried glue. Therefore, such a reflector is not suitable for repeated recovery. With the advent of tape foil, this method is practically not used.

Repairing a headlamp reflector with chrome paint is the most popular. There is no need to cut and glue anything. Paint is sprayed onto the degreased surface of the reflector from a can with white chrome until a uniform, uniform layer is obtained. After painting, the headlamp is dried in accordance with the instructions on the spray can.

Benefits: Provides a smooth surface. You can even spray paint on metal tape, thus increasing the reflective effect.

Disadvantages: Does not tolerate high temperatures. Try to find a heat-resistant chrome paint.

The restoration of the reflector by the method of applying metallized self-adhesive film of the Oracal trademark is considered to be no less effective. Films from the Oracal 351 and Oracal 352 series can withstand temperature drops from -40 to + 120 ° C and, according to the manufacturer, can be used outdoors for two years without deterioration in performance. Since the headlamp is a hermetically sealed space, the life of the self-adhesive film is increased.

The best reflective properties are possessed by a film in the color "Glossy chrome".

It is necessary to make templates from paper or ordinary tape that exactly repeat the shape of the reflector. Then cut the polyester film to the same shape. Using a hair dryer, glue it to the prepared surface of the reflector, smoothing it and preventing the appearance of bubbles. The joints and edges can be additionally treated with chrome paint.

Advantages: reliable manufacturer, excellent reflective effect.

Disadvantages: the price of 1 m 2 starts at $ 5.

Video (click to play).

As you can see, the restoration of headlight reflectors is a simple procedure and is quite possible in a garage.Considering the fact that auto repair shops take an order of magnitude more money for similar work, it always makes sense to try to return the headlight to its previous brightness with your own hands using one of the proposed methods.

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