Headlight Restoration with Sandpaper: Crystal Clear Lenses (600–2000 Grit Guide)

Foggy, yellow headlights not only make your car look old but also reduce nighttime visibility and safety. With the right sandpaper grit sequence, you can restore headlights to crystal clarity without expensive replacements. This guide walks you through the full process.

Why Sand Headlights?

Headlight lenses are made of polycarbonate plastic, which oxidizes and turns cloudy over time. Sanding removes the damaged outer layer, allowing you to polish the surface back to transparency.

Best Tools for Headlight Sanding

• 9x11 in silicon carbide wet/dry sandpaper sheets
• Sanding block or sponge pad
• Spray bottle with water
• Microfiber towels
• Plastic polish or headlight restoration compound
• UV-protective clear coat (optional for longer protection)

Recommended Grit Sequence

• 600 grit: Remove heavy oxidation and yellowing.
• 1000 grit: Smooth scratches from coarse sanding.
• 1500 grit: Refine surface clarity.
• 2000 grit: Final polish-ready finish.

Step-by-Step: Restoring Headlights

1. Clean the headlights. Wash with soap and water, then dry thoroughly.
2. Mask surrounding areas. Protect paint and trim with painter’s tape.
3. Start with 600 grit. Wet sand in horizontal strokes to cut through oxidation. Use 600 Grit (25-pack).
4. Switch to 1000 grit. Sand vertically to remove coarse marks. Try 1000 Grit (50-pack).
5. Refine with 1500 grit. Alternate sanding direction again for uniform clarity. Stock up on 1500 Grit (100-pack).
6. Final sanding with 2000 grit. Light pressure restores transparency and prepares for polishing.
7. Polish. Apply plastic polish with a microfiber towel or buffer until headlights shine.
8. Seal. Apply UV clear coat to prevent future yellowing.

Special Cases

For severely damaged headlights, start with 400 grit before progressing to 600. Always finish with UV protection to extend results.

Pro Tips

• Keep headlights wet at all times while sanding.
• Sand in alternating directions with each grit for even removal.
• Check progress by drying with a microfiber towel before moving to the next grit.
• Use a drill-mounted buffer for faster polishing results.

Aftercare

• Reapply UV sealant every 6–12 months for lasting clarity.
• Wash headlights regularly to prevent buildup of contaminants.
• Store leftover sandpaper in a dry place for future touch-ups.

FAQs

• How long does restoration last? With UV protection, results can last 1–2 years.
• Can I just polish without sanding? No, polishing alone won’t remove deep oxidation.
• Will sanding damage my headlights? Not if you use the correct grit sequence and keep the surface wet.

Watch & Learn

For crystal-clear results, explore our full range of wet/dry sheets in the Super Fine Sandpaper Collection.