DIY repair of cracks in the headlight

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

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:

turbidity 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.

Video (click to play).

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 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.

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 repair of cracks in the headlight

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 repair of cracks in the headlight

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!

you look at how the headlight is made, if you're lucky, it will be sealed on the latches and an elastic band, it seems like this on my Camry (I did not disassemble it, but visually it looks like that) or on a sealant, then you warm the headlight in the oven and remove the glass (just do not overheat, otherwise the plastic will float, the headlight will lead, you will put it back vryatli) and it also happens when the headlight is glued tightly, than something like plastic, then only cut with a boring machine (engraver, dremel)You can try to glue the crack by analogy with the repair of windshields, that is, fill the crack with an adhesive through the injector. there are a lot of topics about this, and there are a lot of videos, look, everything is clear there, but you need a special tool. for car enthusiasts there are "bull's eye" glass repair kits you can try with it.
after repair and polishing
if the headlight is on elastic bands, you put everything back.
in the second variant, you can try to plant it on the old sealant, but it is better to completely remove it and apply “Tape for gluing ABRO glasses” this way it will be better and more accurate.
in the last version you glue back with the same ABRO tape.

Read also: DIY cork valve repair

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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Careless driving or just an annoying accident can cause a crack on the headlight. In principle, if this is a very small chip or crack, then there is no particular reason to fix it. Except for the cases when you do not like its appearance. But if the crack is large, then it is better not to use such a headlamp and start repairing the cracks on your own. The fact is that sooner or later, under the influence of constant vibration, a piece of the headlight can break off.

So, how difficult is DIY headlight repair? In fact, you will not be able to remove the cracks on the headlamp with your own hands, especially if the chips are serious enough, there is no point in restoring such a headlamp and it is much easier to immediately install a new one. We go to the auto parts store and choose an analog or "native" glass for the headlight. At the same time, get a building hair dryer and sealant.

We begin the replacement process. We carefully remove the dirt adhering to the broken headlight. This can be done with an ordinary damp cloth. At the same time, remember that you should not wet the cracked headlight itself, as water can seep inside it. And then a short circuit will already occur and more expensive repairs will be required. Also, before cleaning, it is better to disconnect the negative terminal from the battery. If you see any shards of glass, try to get them out. When doing this, use tweezers or protective gloves.

In more detail, the process of dismantling the headlight for a specific machine model is described in the instructions. But you will almost certainly have to remove the grille first. Next, we are looking for where the headlight mounting bolts are located. After unscrewing them, disconnect the wires from the device and slightly pull the headlight towards you. It should come out of its nest easily. Do not use force, otherwise the headlight may crack in your hands. Most likely, she just got used to somewhere and therefore does not give in. Scrape off the limescale that is holding it and gently pull the headlight again.

We take a hair dryer and lightly heat the edge of the glass.

Using a screwdriver or other sharp object, pry off the headlight glass and discard it. We carefully degrease the edges of the new glass and only then apply the sealant.

We immediately press the glass to the headlight. We warm up the attachment point with a hairdryer for several minutes and remove the excess sealant. It should take at least 10 hours for the device to dry completely. We connect the wires and see how the headlight works.

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:

cloudiness from UV rays;

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.