There are many myths and false statements about cloudy headlights that I will try to clarify.

Cloudy or yellow headlights are becoming a major problem with older cars. They can severely reduce night visibility thus becoming a safety issue. Most modern headlights are manufactured from polycarbonate. This plastic material is very porous and sensitive to ultraviolet radiation from the sun and to acid rain.

To protect the polycarbonate, manufacturers coat the headlight with a primer and a sealer. It is this coating that deteriorates and causes the cloudiness and yellowing. 

Replacement headlights are expensive, with the average cost over $250 each! Some are over $600 each. This doesn't include labor costs to install and re-align the new headlights.

My company manufactures and distributes materials for headlight restoration to dealers and wholesalers. We do not sell to the public nor do we recommend any particular dealers. I have nothing to sell you. The purpose of this guide is to help you make an intelligent decision on restoring your headlights. However, I do have an ulterior motive. Many of our dealers are seeing a growing number of headlights that have been restored by their owners or other dealers that did not include a new protective coating or the owner did not keep the lights properly waxed. This has caused damage to the base material since there was no real protection. This damage is not easily repairable and requires extensive material to be removed from the light. This is causing unhappy customers. Most of our dealers will no longer attempt to restore a previously restored headlight.

95% of all damage to cloudy headlights is on the outside and is limited to the factory protective coating. Headlights with interior damage such as moisture or with severe cracks should not be restored, they should be replaced.

The theory behind headlight restoration is simple. Remove the damaged coating and replace it with a new one. The problem is, most DIY restoration kits remove the old coating but do not replace it. Many kits manufacturers will admit that the results are temporary, or that you must periodically re-coat the lights with wax or some other coating.

About 10% of the kits sold on eBay do include a replacement coating. If you are going to restore your headlights, make sure your kit includes a new protective coating or be prepared to wax your headlights weekly.

Some kits include arbors or abrasive balls to help you remove the old coating. We do not recommend using power tools to remove the old coat. If you do, you run the risk of burning the polycarbonate and you also must mask off around the light to protect the paint. For a single set of lights, sand by hand. It's cheaper, safer and gives you greater control.

Kit prices vary from $5.95 (one ounce of rubbing compound) to over $60 with shipping. You don't always get what you pay for. Many kits are big on hype but short on details. If you really want to save money, just rub out your headlights with toothpaste and wax weekly. If severely damaged, start with 600 grit sandpaper followed by 1200 grit, etc. then polish with toothpaste. This will give you the same results as many of the inexpensive kits on the market.

There are now some major players in the headlight restoration market; Permatex, Mopar, Wynn's, Mopar, 3M and others. The interesting thing is that most of these kits do not replace the protective coat. They only sand and polish. There are a few reasons for this, such as product liability and cost. The main material for our protective coat costs us over $1200 for 5 gallons.

Many kits include a guarantee. If you're not completely satisfied, you get your money back. But how can you guarantee that the DIYer will use your product correctly? More importantly, you might get your money back, but what about the condition of your headlights? Have you caused more damage trying to restore them?  

Many kits don't really explain their procedure in their ads. Know what you're getting. Here's the questions to ask:

Does the kit include a replacement protective coating? If so, is it permanent? Is it warranted not to deteriorate?

What's included in the kit?

Are MSDS (material safety data sheets) included or available from the manufacturer? Do you know what chemicals are in the kit?

Can you view the instructions or see a demo video clip before buying?

To summarize, most headlights can be restored and you can do it yourself. If this is what you want, do some research and choose wisely. Don't spend a few hours carefully sanding and polishing you lights without replacing the protective layer you removed.

As an alternative, headlight restoration is becoming big business and many areas have dealers and contractors available to restore headlights. Although more expensive than doing it yourself, these people are capable of restoring most headlights to near new condition at a fraction of the cost of headlight replacement.

Ray Raffa