How to Sand Plastic Headlights for Restoration (400, 600, 1000, 2000 Grit Guide)

Cloudy, yellowed headlights reduce visibility and make vehicles look older than they are. Sanding is the first and most important step in headlight restoration. By using the right grit sequence, you can remove oxidation and scratches, restoring clarity and brightness. This guide explains how to sand headlights step by step using 400, 600, 1000, and 2000 grit sandpaper.

Why Sanding Headlights Works

Plastic headlights oxidize and develop a rough, cloudy surface over time. Sanding removes the damaged outer layer, exposing fresh plastic that can be polished and sealed. Without sanding, polishes and coatings won’t bond properly, and haze quickly returns.

Tools You’ll Need

• 400–2000 grit wet/dry sandpaper – essential for stepwise smoothing.
• Sanding block or pad – keeps surfaces even.
• Water spray bottle – prevents melting and clogging.
• Headlight polish & UV sealant – restores clarity and prevents re-oxidation.
• Microfiber cloths – clean between each step.

Best Grit Sequence for Headlight Sanding

• 400 grit: Removes oxidation and deep yellowing.
• 600 grit: Refines scratches and evens surface.
• 1000 grit: Smooths surface before final sanding.
• 2000 grit: Leaves a haze-free finish ready for polishing.

Step-by-Step Headlight Sanding

1. Start with 400 grit. Wet sand evenly to strip oxidation using 400 grit (100-pack).
2. Smooth with 600 grit. Refine sanding marks using 600 grit (25-pack).
3. Refine with 1000 grit. Achieve a semi-clear finish with 1000 grit (25-pack).
4. Finish with 2000 grit. Wet sand lightly for a polished surface using 2000 grit (100-pack).
5. Polish & seal. Use headlight polish, then apply UV sealant to protect against future haze.

Special Cases

For extremely yellowed headlights, start with 320 grit before moving up. For minor haze, you can start directly at 600 grit. Always keep surfaces wet to prevent heat damage to plastic.

Pro Tips

• Mask off surrounding paint to avoid accidental scratches.
• Sand in horizontal, then vertical strokes with each grit for consistency.
• Apply UV sealant after polishing—without it, haze will return quickly.
• Replace sandpaper often—plastic dust clogs sheets fast.

Aftercare

• Wash headlights regularly with car-safe soap.
• Reapply UV sealant every 6–12 months for lasting clarity.
• Inspect for chips or scratches—lightly re-sand with 2000 grit if needed.

FAQs

• Can I use a drill with sanding discs? Yes, but hand sanding gives better control and prevents overheating.
• Do I have to polish after sanding? Yes—polishing restores transparency and gloss.
• Will sanding make headlights weaker? No—it only removes the damaged outer layer.

Watch & Learn

For crystal-clear results, explore our super fine sandpaper collection.