How to Sand Car Headlight Lenses for Restoration (600, 800, 1500, 2000 Grit Guide)

Faded or cloudy headlights not only look bad but also reduce nighttime visibility. Sanding is the foundation of every headlight restoration process. With the right grit progression, you can remove oxidation, scratches, and haze, restoring headlights to crystal clarity. This guide explains how to sand headlight lenses step by step using 600, 800, 1500, and 2000 grit sandpaper.

Why Sanding Headlights Matters

Headlights are made of polycarbonate plastic, which oxidizes over time due to UV exposure. Sanding removes the damaged outer layer, exposing fresh plastic that can be polished and sealed. Skipping sanding leaves haze and prevents coatings from bonding.

Tools You’ll Need

• 600–2000 grit wet/dry sandpaper – for progressive smoothing.
• Sanding block or pad – ensures even sanding.
• Water spray bottle – keeps sanding cool and dust-free.
• Headlight polish & UV sealant – restores shine and prevents future yellowing.
• Microfiber cloths – for cleaning between stages.

Best Grit Sequence for Headlight Sanding

• 600 grit: Removes oxidation and deep haze.
• 800 grit: Refines scratches left by coarse sanding.
• 1500 grit: Smooths the surface for polishing.
• 2000 grit: Leaves a haze-free, polish-ready finish.

Step-by-Step Headlight Sanding

1. Start with 600 grit. Wet sand oxidation evenly using 600 grit (25-pack).
2. Smooth with 800 grit. Refine scratches with 800 grit (25-pack).
3. Refine with 1500 grit. Wet sand for a near-clear finish using 1500 grit (50-pack).
4. Finish with 2000 grit. Prepare for polishing with 2000 grit (100-pack).
5. Polish & seal. Use compound and UV sealant to restore clarity and prevent yellowing.

Special Cases

For heavily oxidized headlights, start with 400 grit before moving to 600. For minor haze, you can begin at 800 grit. Always finish with 2000 grit before polishing for the clearest results.

Pro Tips

• Mask off surrounding paint to avoid accidental scratches.
• Always wet sand to keep the plastic cool and avoid damage.
• Work in straight strokes, alternating directions with each grit.
• Apply UV sealant immediately after polishing to lock in clarity.

Aftercare

• Reapply UV sealant every 6–12 months for lasting clarity.
• Wash headlights regularly with mild soap.
• Lightly re-sand with 2000 grit if haze reappears.

FAQs

• Can I dry sand headlights? No—always wet sand to prevent scratches and melting.
• Do I need to polish after 2000 grit? Yes—polishing restores transparency and gloss.
• Will sanding weaken the plastic? No—it only removes the oxidized outer layer.

Watch & Learn

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