In detail: DIY repair of plastic headlights from a real master for the site my.housecope.com.
The optics of a car during its operation are very susceptible to mechanical stress. This can happen due to the carelessness of the car owner himself or as a result of a collision. Today, all damaged parts can be replaced with new ones, just buy them in the store.
the refurbished headlight looks like new
But often they are quite expensive (and finding spare parts for some cars is also quite problematic), so most car owners prefer to repair themselves.
The integrity of the optics can be restored in different ways, depending on the degree of its damage. For work, you may need special tools and a welding machine with a compressor. The fragments of the headlight are welded to them in case of violation of its integrity.
Headlight repair must begin with determining the material from which the optics are made. ... If the headlight is plastic, it can be repaired using cold welding, polypropylene optics can be restored using welding.
You also need to remember that when trying to connect different types of materials to each other, you should not rely on a strong connection.
The restoration of headlights is carried out not only in the case of their mechanical damage, but also with a slight haze. It greatly affects their ability to transmit light, and this can cause accidents at night. Common optical defects that a car owner may encounter:
Headlamp housing cracks
Damage to the elements of its fastening,
Depressurization of seams,
Various scratches and chips that occur during the operation of the vehicle.
Video (click to play).
Headlamp fogging is a seemingly minor problem that car owners usually don't pay attention to. But if such a defect is not removed within 1-2 months, the mirror layer of the deflector may begin to collapse. Due to the accumulation of moisture in this place, problems with oxidation of contacts, etc., may also begin.
Scratches on optics are a fairly common phenomenon and they also do not always get enough attention. The headlamp must be sanded and carefully polished. With this repair, you can get rid of even deep scratches and improve the appearance of the vehicle's optics.
Also on the headlight, you can find plaque that forms on the inside. The reason for its appearance may be the ingress of chemical reagents (usually with a contactless car wash). When exposed to high temperatures, such deposits can form a cloudy film and impair the ability of the headlamp to transmit light.
It is better to eliminate such a flaw in specialized auto repair shops, since it can be quite problematic to do the work with your own hands. The cracking of the headlight cover, which is found on many modern cars, is also a serious problem.
It can deteriorate over time due to natural causes, exposure to ultraviolet light or the negative effects of chemicals. In some cases, it is impossible to completely remove such a defect, because it is impossible to get to the damaged area either with your hand or with the help of special equipment.
If you are not confident in your abilities and the necessary practical skills, it is not recommended to restore plastic headlights. Indeed, in this case, there is a high risk of additional destruction of the plastic of the optics or its mirror layer.
Before starting all work, it is necessary to thoroughly clean the headlamp and conduct a careful visual inspection of the defect. Thus, it is possible to identify the presence of cracks in it, which must be completely eliminated. If this is not done, under the influence of constant vibrations, the network of cracks will expand and ruin the entire appearance and transmission capacity of the headlight.
If no such flaws were found, you can start repairing car headlights with your own hands. Repair of chips and scratches must be performed in full accordance with the technology and in the following sequence:
The cleavage site is thoroughly washed and completely dried.
In the center of the damaged area, it is necessary to install an injector, with its help, a polymer mixture is supplied for gluing.
The volume of the chip is filled with an adhesive, and care must be taken to avoid the formation of air bubbles.
After that, the injector is removed and the glue must be dried using an ultraviolet lamp. Repairing the headlamp reflector can be done in the same way.
Then, in order for the repaired site to have increased strength, it can be additionally treated with a hardener.
After the mixture has completely solidified, all surface irregularities are removed with a file. After that, the headlamp is polished using a grinder or fine abrasive paper, and then final polishing is carried out to give the optics a shine.
Repairs can be done in various ways, but the simplest method to remove defects from a plastic headlight is to weld it with hot air. In this way, the split-off parts of the optics can be returned to their place (the gluing method is not very effective in that case).
In the process of performing work, you need to remember one important detail - only one type of plastic can be welded. Failure to comply with this condition can lead to the fact that the repaired headlamp will last no more than a couple of weeks.
Repairing the headlight mounting is a much more complicated procedure and it is better to entrust the work to professionals. Welding this section will be ineffective and soon the headlight will become unusable again, so experienced craftsmen recommend repairing the headlight housing using prosthetics. Some metal parts are being replaced with others and the headlight is taking on its position.
To repair the headlight in the event that it has lost its transparency, you can use polishing and grinding. The dullness of the headlights is acquired due to the mechanical effect of particles that rise from the road surface during the operation of the car.
As a result, not only clouding, but also chips can form. At the manufacturing plant, polycarbonate is often used in the production of automotive optics. Such material is very durable, but its distinctive feature is that it is not resistant to mechanical stress and ultraviolet radiation.
Therefore, on top it is additionally covered with a special protective layer, which for some time protects the optics from the effects of negative environmental factors. In the process of repairing the headlight, it is very easy to damage this layer, and after removing it, after a couple of months, the headlight will need to be additionally polished due to defects that rapidly appear on it.
VIDEO Therefore, in the process of performing work, it is necessary to apply a fine polish, which practically does not harm the protective layer of the optics. To remove deep chips and scratches, you yourself have to remove the protective layer applied at the factory, since it is simply impossible to do the work differently.
After the repair is completed, in order to further protect the headlight, it is recommended to cover it with an anti-gravel film.
VIDEO
We repair headlights after an accident or minor accidents. If you have a broken headlight housing, mount or glass, this is not a reason to buy a new headlight.
soldering cracks on the body from the inside and outside using special equipment;
restoration of missing plastic elements;
restoration of missing headlight mounting ears;
headlight mounting repair;
replacement of fasteners of the corrector and the internal reflector of the headlight.
It often happens that the glass of the headlight is covered with cracks, multiple chips, or breaks as a result of an accident.
In stock and to order glass for many brands and models of cars.
Repair in such cases is not possible, the situation can be corrected only by replacing the headlights. Our company replaces the glass of the headlights with new or used glass. If you already have glass or have a donor (any used headlight from disassembly, with a whole glass), then we can remove the headlight glass from the donor and install it on your headlamp with high quality and with a guarantee.
One of the most common problems with front optics is the leakage of the headlight housing.
The main reasons for headlamp leakage are:
the formation of microcracks through which moisture enters;
when replacing the lamps, moisture got inside;
deformation or contamination of the rubber seals of the rear covers;
the use of low-quality sealant;
ingress of moisture when washing the engine compartment.
The experience of the masters of the laboratory "Avtoprisma" allows you to accurately diagnose the problem of fogging and eliminate it in the shortest possible time. Avtoprisma specialists use only proven materials and tools when repairing headlights. We can guarantee the result and the problem of fogging headlights will not bother you again.
During the operation of the car, the inner surface of the glass of the headlights fades over time. Cloudy headlights have reduced transparency and increased scattering ability, which leads to the fact that the driver does not see the objective situation on the road at night. Routine washing will not get rid of the resulting cracks and minor scratches on the headlights - they need to be cleaned. And here the internal polishing and cleaning from the inside of the headlights in the Avtoprisma company will help.
Automotive optics are fragile and quite expensive. In addition, it is quite difficult to find replacements for old headlights on some models. Therefore, many motorists, instead of buying new headlights, prefer to do many work on their own or contact specialized companies like ours.
The possibility and method of restoring auto-optics depends on the degree of damage and the material from which it is made. So, in order to repair headlights after an accident, replace headlamp glasses, remove a crack, etc., you may need a set of automotive tools, a welding machine, and a compressor.
Today we will look at how to cope with the most common defects in headlights: cracks in the case, damage to mounts, chips, scratches, and clouded glass.
First, rinse and dry the chip area on the headlamp or reflector.
Place an adhesive gun in the center of the problem area.
Fill the damaged area with adhesive, avoiding the formation of bubbles.
Remove the compressor and cure the adhesive with a UV lamp.
Treat the area with hardener.
After the final solidification, process the area of the former chip / crack with a file, and then with a sander or sandpaper.
Buff the surface to shine.
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 means: - maintaining 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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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
Polycarbonate optics
cloudiness due to ultraviolet rays;
poor resistance to the effects of various alkalis, acids and other corrosive liquids;
relatively short service life.
Acrylic headlights,
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
VIDEO
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.
VIDEO
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.
The seam should be welded both from the outside and from the inside in order to provide the headlights with the required 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.
VIDEO
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.
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!
VIDEO
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 should be noted 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 refurbishing 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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VIDEO
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 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 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 hydrocorrector
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VIDEO
Car owners are often interested in how to make plastic headlight repairs. The advantage of the product is the possibility of self-repairing the case. This will require a sealant or warm weld. Due to the action of the hot stream, the plastic melts, after which the product is given the required shape. It remains only to connect the broken part of the part to the damaged element. In this case, remember that the elements to be connected must be made of identical plastic. For fastening, you can also use a sealant.
The restoration of the headlamp includes one more work - the repair of fasteners, which often fail on plastic products. To solve the problem, do not use welding or sealant, because in this case, the fasteners will not last long. The best solution is to make prosthetics by specialists at the service station. To eliminate yellowness on the surface of the headlights, you can use other options, for example, polishing.
Correct restoration of headlights and restoration of glass allows you to improve the quality of the lantern glow, as well as minimize the risk of getting into an accident at night.
When using a car, optics are subject to various mechanical damage, which they get in a collision or through the driver's carelessness. The modern market allows replacing any damaged part. However, given that their cost is considerable, many car owners prefer to repair their car headlights on their own.
Professionals consider glass headlights to be of the highest quality. They look beautiful, do not grow cloudy, last longer and have ideal light transmission. However, they are more fragile than plastic counterparts, and are also prone to cracks and scratches. To protect the glass, a special film is used that reliably protects against impacts.True, it somewhat reduces the light transmittance, but this is nothing compared to the cost of replacing damaged optics.
Polycarbonate headlights are significantly cheaper and more practical. They are resistant to detergent solutions, temperature changes, mechanical damage. However, they have significant disadvantages:
instability to alkalis, acids and other corrosive liquids;
are distinguished by a short operational period.
Acrylic optics are known to motorists as headlights made of plexiglass, which are of better quality than polycarbonate ones and take on all sorts of shapes when heated. However, when solidified, the degree of their transparency is significantly reduced. Acrylic headlights do not grow cloudy, but they can crack under significant temperature changes.
Depending on the type and degree of damage, there are various ways to restore optics. The work may require the use of a specialized tool, as well as a welding machine equipped with a compressor, which will weld the fragments of destroyed optics.
The repair begins with the identification of the materials used in the manufacture of the optics. Cold welding is used for plastic products. It should be understood that acrylic is not interchangeable with polycarbonate and the bond will not be strong.
VIDEO
The headlights are restored both with the formation of mechanical damage and with slight turbidity, which affect the light transmission capacity and are capable of provoking a night traffic accident. Also, plaque can form inside the headlamp, causing clouding and deterioration in the quality of light transmission.
Before starting the restoration, the headlamp should be cleaned, carefully examine the defect to detect cracks that require complete elimination. You need to understand that vibration tends to expand cracks, deteriorating the throughput, as well as the appearance.
If there are no such flaws, they begin to restore the optics, following the existing technologies.
Thoroughly washed cleavage is well dried.
An injector is installed in the center of the defect, which supplies the polymer mixture.
When filling a chip, the formation of air bubbles should be excluded.
The injector is removed and the glue is dried with a UV lamp. The headlight reflector is restored in the same way.
To give strength, the repaired section of the glass is treated with a hardener.
After the composition has solidified, the surface roughness is removed with a file.
There are various ways to eliminate defects in plastic headlights. Among them, the most effective and simplest is welding with hot air, which makes it possible to recover chipped particles.
Video (click to play).
When welding plastic glass, it should be remembered that the work will be successful only when joining homogeneous materials. Otherwise, the headlamp will not last long.
