Do-it-yourself headlight chip repair

In detail: do-it-yourself headlight chip repair from a real master for the site my.housecope.com.

The traffic police inspector wins a "lemon" in the lottery. They ask him:
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- Buy a crossroads and work for the soul!

Service “Headlight glass repair” focused on repairing damage to headlights and foglights. Headlight glasses are made of tempered glass. The blow of a stone, as a rule, leads to a through hole, and a large fragment of glass breaks off from the inside. Through holes depressurize the headlight, and in addition to the fact that the headlight begins to “sweat”, dirt and moisture get there. Accumulating, dirt and dampness over time cause the reflector to "cloud" and peel off the glossy reflective coating, and the light of the headlight loses its brightness.

Headlight glass repair differs from the repair of windshields, primarily by the polymer used, but 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. On most cars, when it becomes necessary to replace the headlight glass, you have to purchase the entire headlight unit, since glasses that can be replaced are produced for single models.

To date, the headlights of almost all cars are equipped with impact-resistant plastic, damage to which is extremely rare. Over time, the outer surface of plastic headlights turns yellow and becomes dull. This defect is eliminated by polishing.

Shock-resistant, transparent film with a thickness of 0.5 - 1 mm, when glued, repeats the contours of 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 pasted on 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 water.

Video (click to play).

Below is the headlight glass repair technology.

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

glass headlights. The most high-quality and efficient specialists are considered optics made of glass. It looks beautiful, stylish, perfectly transmits light, is used longer and does not become cloudy. At the same time, such headlights, in comparison with other analogues, are more fragile, highly susceptible to scratches and cracks. To protect the glass, a special film is used. It provides reliable protection against impacts with small stones, it can be wiped without fear of scratching the glass. However, the coating reduces the transmission capacity 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:

clouding under the influence of ultraviolet rays;
poor resistance to various alkalis, acids and other aggressive liquids;
relatively short service life.

acrylic lights, better known as plexiglass optics. Acrylic, compared to 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%. These optics do not become cloudy, but are more prone to cracking with significant temperature fluctuations.

To repair the headlights, you will need the following tools:

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

Depending on what the damaged optics was made of, we prepare the appropriate material. The best option are fragments 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, adhesive tape and a special molecular adhesive. 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 headlight are repaired with a hair dryer in the following sequence:

Arrange the fragments in the correct order. If some parts are lost or cannot be restored, use parts from previously repaired optics.
Each piece is alternately heated with a hair dryer and attached 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, the restored optics are carefully ground and polished using a felt wheel.

Broken pieces of headlights can be glued together with special glue. The repair procedure is similar to the above sequence. If you lack the necessary parts, you can make them yourself from plexiglass. All seams must be treated with a hardener on both sides.

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

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

Preparing a template. We fold the destroyed optics in parts, replace the lost elements with ordinary plasticine. Then we make a plaster matrix.
We cut a blank of the desired size from plexiglass.
On the tracing paper we draw a template of the internal glass pattern with a caliper.
With the help of a milling machine on a Plexiglas blank, we reproduce the optics pattern with maximum accuracy.
After that, the plexiglass is applied to the gypsum matrix and packed in a heat-resistant vacuum bag.
We heat the resulting package until the plexiglass is completely softened and with the help of a compressor we 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.

Repair of rear lights is carried out in a similar manner. First, parts of the destroyed optics are laid out on the table. Then, in the desired sequence, we glue the existing elements with glue.

As a rule, some parts after an accident will be lost or destroyed beyond repair. Therefore, it is necessary to prepare spare parts from a similar lantern. First, we prepare a template for the missing element and, using it, we 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 gluing, 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 with a drill.
Rinse and dry the surface.
We install an injector strictly above the crack and apply 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 sealing cracks, it is recommended to treat the seams with a 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 circle. It is not recommended to press hard to avoid overheating of the plastic. The time of one procedure should not exceed 3-4 minutes.

After rough grinding, we proceed to polishing. To do this, apply napkins and polish. A small amount of the mixture is applied to the napkin and the surface is manually polished for 6-8 minutes. You can process plastic headlights using a grinder. In this case, low speeds should be used and the surface should not be overheated.

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 headlights or lanterns is repaired by welding with hot air injection. For these purposes, a special soldering iron is used, which “feeds” on the compressor air. With the help of a hair dryer, pieces of the body are returned to their place and attached. Usually you have to repair cracked or broken headlights, so the fragments may not be enough. In this case, spare parts for headlights that have been repaired before will come in handy. Image - Do-it-yourself 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 you start work, you should find out what plastic the case was made of. It could be ABS 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 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 table. This is where the gypsum matrix is made. Then you should cut a piece of plexiglass of the desired size. Typically, a headlight requires clear glass up to 6 mm thick, and for sidelights or fog lights - no more than 5 mm.

Next, you need to take a tracing paper and draw an internal drawing of the old glass. To measure everything very accurately - use a caliper. Taking a template, a pattern 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 done actions, both the gypsum matrix and the plexiglass are packed in a vacuum heat-resistant bag. The next step will cause difficulties for many, but it only seems. You should find a special machine or workshop where you will be allowed 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 pressure of the outside air gives the glass the shape of gypsum.Note that these steps help to make only the front of the headlight, but the "sides" are made separately and attached later.

Broken pieces of caps from lanterns 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 from the same plexiglass of a suitable color. After everything is glued, the seams are treated with a hardener. The adhesive must be handled with care as it can cause burns if it comes into contact with the skin. Image - Do-it-yourself headlight chip repair

The irregularities of the seams on the headlight are removed with a file, processed with sandpaper and polished with GOI paste and a felt wheel. It will not work to completely eliminate the seams, but they will not affect the quality of the light.

If you need to fit the plexiglass to an old cap, the material is heated with a hair dryer and shaped by hand. Caps of complex shapes are driven by a vacuum press. The cap is glued to the lantern body with polyurethane sealant.

The new headlights of your car will be stronger than the "relatives", because they will withstand even a blow from a stone. The only thing is that this material can become cloudy or scratched. We also take into account the fact that fog lights can crack due to snow or cold rain, but plexiglass is not afraid of low temperatures.

Good luck with your headlight repair!

The optics of the machine are subjected to heavy mechanical loads, which can lead to damage to these elements. The reason may be the carelessness of the car owner on the road or getting into an accident. Repairing a headlight is not difficult. All you need is a tool, replacement parts, and fastener sealant.Headlight restoration is required in a situation where deformation or damage leads to a deterioration in the light transmission of the product. As a result, the risk of getting into an accident when driving at night increases. In addition, the yellowed plastic is not the most presentable.Common headlight defects faced by car owners include:

The appearance of cracks on the glass.

Violation of tightness at the joints.

Damage to the body and fasteners, scratches and chips.

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

The problem may occur if chemicals get inside the product. Under the influence of high temperatures, plaque appears on the outer part of the glass, which reduces the throughput of the headlight. In addition, due to the appearance of an extraneous "film", the glass may acquire a yellow tint. In this case, to restore the headlights, it is better to involve professionals.

The appearance of scuffs or chips on the surface of the headlight can cause it to fog up. If the defect is not eliminated in a timely manner, the mirror layer is broken, and the lantern requires repair. Moisture also has a negative effect, the ingress of which leads to the oxidation of contact joints. That is why, when fogging, it is important to quickly solve the problem and repair the headlight. To restore tightness, you can use a sealant.

Why the headlight sweats, 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, grinding and polishing of the surface is used. With the right approach, you can return the original appearance of the glass. Repair of a lantern is desirable to be done only if you have experience, self-confidence and knowledge of the technology for performing work.

car headlight polishing

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

To repair a headlight, do the following:

Prepare the problem area - clean it, wash it and dry it.
Fill the cavity with adhesive.Make sure that no bubbles appear during the procedure.
Use a UV lamp to dry the repair site.
Fix the result. To do this, cover the existing crack with a hardener.
Polish the restoration site with a grinder or sandpaper.

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

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

Alternatively, when repairing the reflector, metal foil or film can be used, followed by fixing with sealant.

Video: How to properly restore headlights

If the video is not showing, refresh the page or ” style=”color:#CC3333″>click here

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

Remove the corrector knob.

Unscrew the fixing nut and remove the master cylinder.

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

Remove the scale backlight to easily dismantle the hydraulic corrector.

Discard the headlights of the machine from the working cylinders.

Remove the corrector assembly.

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

Video: Repair of headlight hydrocorrector Lada GrantaIf the video is not showing, refresh the page or ” style=”color:#CC3333″>click here

The easiest way to eliminate defects in plastic is hot air welding. A polypropylene headlight can be given a second life with conventional welding. Welding seams 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 different types of plastic will last no more than 1-2 weeks.

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

Over time, headlights can acquire a matte color due to the constant impact of rising asphalt particles. In addition, optics made of polycarbonate lose their transparency even under the influence of 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. Upon completion of work, it is recommended to apply an anti-gravel film.

Plaque on the inside of the headlight occurs due to the ingress of chemicals during a contactless car wash. Under the action of high temperature, it is converted into a cloudy film that worsens the light transmission of the optics. For the same reason, the protective film may crack. In most cases, it is problematic to completely eliminate these defects due to the difficulty of access to the inner surface. Without experience in this work, you can further destroy the plastic or the mirror layer of the headlight. Therefore, it is better not to take risks and contact a specialized car service.

It often happens, especially after an accident or a large stone hitting the headlight glass, that it is not possible to restore it and replacement is required. To completely replace it, you need to purchase 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 to the headlight. If the sealant on the headlight is thermally collapsible, then this is not so difficult to do, you can use a building hair dryer, the main thing is to do it carefully and not overheat the plastic of the headlight. If the sealant on the headlight is not thermally sealed, then I'm 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 accessory installation center. 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 provide a 1 year guarantee for the work carried out by us. We specialize in installation/replacement of Bi-Led and Xenon lenses, repair and improvement of standard headlights. Any work with autolight and backlight. All equipment is in stock, installation in your presence.

Installation of additional equipment in the service center "Avtoprisma" is: - preservation of the warranty on the car - 1 year warranty on work - accurate and honest advice - individual approach - confidence in the quality of work - fulfillment of the order 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 why a car headlight fails. The headlight, in addition to the lamp, includes other elements - a washer, a reflector, a diffuser, a hydraulic corrector and other elements, the malfunctions of which must be eliminated as soon as possible after detection. For what reasons do car headlights break down, how are car headlights repaired, and what are the features of repairing individual 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:

Repair of the headlight corrector may be needed for three common reasons:

Sensor failure, as a result of which the readings are distorted or disappear altogether.
Poor contact connection, negatively affecting the readings of the device.
The specifics of the car model are a small adjustment angle and other features.

Regardless of the reasons why the car headlights broke down, it is necessary to carry out troubleshooting work and restore standard lighting in a timely manner.

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

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

Thoroughly clean the place of the crack, wash and dry until completely dry.
In the central part of the defect, install an injector to supply the adhesive mixture.
Fill the crack with adhesive to prevent air bubbles from forming.
Dry the glue by first removing the injector (drying is done with a UV lamp).
Cover the repaired defect with a hardener to fix the result.
The final stage is polishing with emery or a grinder.

On this, the restoration of the headlights is considered complete. This is only a small part of the work that an ordinary motorist may encounter. It is often necessary to restore the headlight reflector. For this, the following methods are used:

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

Sometimes the restoration of the headlight reflector is not possible due to serious damage - partial or complete melting under the influence of high lamp temperatures. In this case, you can make a reflector with your own hands or purchase a finished product in a specialized store. It is important to select a model recommended by the manufacturer, and when making it yourself, carefully monitor compliance with this compliance.

Headlight washer repair often consists of cleaning the mechanism of accumulated dust and dirt - WD-40 or an oil similar in properties is used for this purpose. You can reduce the likelihood of washer breakage by using it regularly, preferably at speed.

The headlight hydraulic corrector is designed to change the direction of the light beam. A breakdown of the device limits the possibility of adjustment, therefore, the repair of the headlight hydrocorrector should be carried out immediately after a malfunction is detected. If repair of the headlight corrector is not possible, it must be replaced:

Remove the hydraulic corrector handle and remove the main cylinder, which is secured with a fixing nut (it must be unscrewed).
Remove the cladding, scale and light guide by unscrewing the elements with a screwdriver.
Remove the scale backlight that prevents the corrector from being removed.
Disconnect the working cylinders from the car headlights.
Remove the hydraulic corrector in its entirety.

Installing a new device is done in reverse order.

Do-it-yourself headlight repair is made easier if you are dealing with a plastic construction. You can remove external defects by means of heat welding - with powerful streams of hot air, the necessary part of the structure is melted, after which it is given the desired shape or the breakaway part of the headlight is attached. The main rule is that heat welding is performed only between parts made of the same plastic.

The 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 a complex repair of car optics.

The headlight, like any part of the car, wears out over time, as evidenced by a less bright and blurry beam. The 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 headlight 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 winter. Therefore, the possibility of encountering this problem cannot be ruled out.

Often the cause of damage to the reflector is a violation of tightness. Small particles of dust and moisture get inside, which lead to the loss of reflector luster. As a result, the quality of the light flux gradually decreases.

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

Whatever the cause, the reflector must either be replaced or rebuilt. The cost of restoring one reflector in a car repair shop is at least 1 thousand rubles, which is not acceptable for every motorist.Therefore, we propose to consider a few simple ways to restore the headlight reflector with your own hands.

To get to the reflector, the headlight dismantled 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 involves leaving the headlight in an oven heated to 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 headlight components together begins to break down 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 30 rubles. Its adhesive base perfectly copes 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, pieces of the most suitable shape are first formed from several strips. Then remove the protective film and gently paste. The whole procedure takes about half an hour.

Immediately before gluing, the surface must be degreased.

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

Disadvantages: when sticking, irregularities and seams remain, which worsen the properties of the reflector.

Aluminum foil has a high reflectivity, which makes it suitable for the restoration of headlight 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 changes.

Disadvantages: Being between the metal foil and the plastic base, the epoxy glue is deprived 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 adhesive tape, this method is practically not used.

Headlight reflector repair with chrome paint is the most popular. No cutting and gluing required. Paint is sprayed onto the degreased surface of the reflector from a can of white chrome until a uniform uniform layer is obtained. After painting, the headlight is dried in accordance with the instructions on the 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. You should try to find heat-resistant chrome paint.

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

The film has the best reflective properties in the color "Chrome glossy".

From paper or ordinary adhesive tape, it is necessary to make templates that exactly repeat the shape of the reflector. Then cut the polyester film in the same shape. Using a hair dryer, stick it on the prepared surface of the reflector, smoothing and preventing the appearance of bubbles. Docking points and edges can be additionally treated with chrome paint.

Advantages: reliable manufacturer, excellent reflective effect.

Disadvantages: the price of 1 m2 starts from $5.

Video (click to play).

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

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