How to Sand Headlights

Headlights (Polycarbonate): If your goal is to restore shine, sanding is all about control: consistent pressure, a sensible grit progression, and checking your scratch pattern under good light. Below is a repeatable workflow that keeps you from over-sanding while still getting a smooth, uniform surface.

Why Sanding Matters

Most “bad finishes” come from uneven scratch patterns—either skipping grits, pressing too hard, or sanding without a flat reference (like a block). The right grit sequence levels the surface first, then progressively refines the scratches so your final finish (or polish) looks even.

Recommended Tools

• Sanding block (firm for flat areas, flexible for gentle curves)
• Spray bottle with clean water + a drop of dish soap (for wet sanding control)
• Microfiber towels and a lint-free cloth
• Masking tape to protect edges and adjacent finishes
• Bright task light (raking light) to reveal scratches/texture

Recommended Grit Sequence

• 600 grit — pre-finish smoothing
• 800 grit — pre-finish smoothing
• 1000 grit — pre-finish smoothing
• 1500 grit — pre-finish smoothing
• 2000 grit — pre-finish smoothing
• 3000 grit — pre-finish smoothing

Step-by-Step

1. Prep the area: clean headlights (polycarbonate) thoroughly, then dry-wipe so grit doesn’t get dragged across the surface.
2. Mask anything you don’t want to sand (adjacent finish, glass trim, hinges, or sharp corners that burn through fast).
3. Start with 1500 Grit (10-pack) using light, even pressure. Keep the block flat; let the abrasive do the work.
4. Switch directions every few passes (crosshatch). This makes it obvious when the previous scratch pattern is fully removed.
5. Move to 2000 Grit (10-pack) to refine. At this stage you’re replacing deeper scratches with finer ones.
6. For wet sanding: mist the surface, keep it uniformly damp, and wipe slurry often so you can see progress.
7. Finish with 3000 Grit (10-pack) for a consistent, finish-ready surface. Stop as soon as the texture looks uniform under raking light.
8. Clean again: vacuum/wipe, then a final damp microfiber pass. Any leftover grit will telegraph into your finish or polish.

Special Cases

Profiles & grooves: wrap paper around a foam pad to match the shape without rounding crisp lines. Veneer risk: if the piece is veneered, stay conservative—use the least aggressive grit that still cuts.

Pro Tips

• Use raking light (flashlight at a low angle). If you can still see the previous scratch direction, you’re not ready to move up.
• Don’t jump grits too far. Small steps save time because each grit removes the previous pattern faster.
• Change paper when it stops cutting. Dull paper makes you press harder (and that causes uneven sanding).
• Keep pressure even across the block—especially near edges where burn-through happens first.

Aftercare

• Remove masking tape carefully and wipe the surface clean one more time.
• If you’re painting or coating wood, apply a compatible primer/sealer and sand lightly between coats as needed.
• For glass clarity, follow sanding with a polishing step (compound + pad) until the haze is reduced.
• Store unused sheets flat and dry so they don’t curl or contaminate with dust.

FAQs

• Can I wet sand this? Yes—silicon carbide sheets are suitable for wet or dry use; wet sanding often helps control dust and scratch depth.
• How do I know when to switch grits? When the entire area shows only the current grit’s scratch pattern, with no leftover lines from the previous step.
• What if I sand through a finish on wood? Stop, feather the transition, then plan to recoat the entire panel for a uniform sheen.
• Do I need a power sander? Not for small areas—hand sanding with a block is safer for edges, corners, and controlled leveling.

Watch & Learn

Tip while you watch: pause at the grit-change moments and compare scratch direction. If your scratch pattern doesn’t fully “flip” to the new direction, stay on the current grit a bit longer before moving up.

Need sheets in the exact grit you’re using today? Explore the full selection here: silicon carbide sandpaper sheets.