Refinishing Headlights/Installing Angel Eyes

[540IForMe]

Thanks guys and FP, dead sexy. I really like the bumper and chrome/black kidneys.

[siny528i]

Thanks guys and FP, dead sexy. I really like the bumper and chrome/black kidneys.

I cant believe nobody can answer my questions... I guess I will have to improvise. Thanks!

[JoshuaM5]

Very helpful DIY,
Well represented , keep it up.

[540IForMe]

They issue I have is to find correct AE kit. I found a lot of them on eBay.
I know I want white ones, but which like brand names or where from?

Thanks in advance,
siny528i

Outstanding work! Sexy ride BTW! I would never guess its not DLRs!

Did you polish them as well?
What kit and where from did you use if its not big secret?
Looks like AE in front of the lenses, arent they?

I don't know if the guy I bought from is still selling them but they are all generally the same. Check this auction out:

http://cgi.ebay.com/ebaymotors/BMW-E...Q5fAccessories

Probably work just fine. They look like mine.

And FP's AEs look to be on the outside of the lenses like mine.

[quik96M3]

Over the past few evenings I attempted the headlight lens restore as described here on my 2004 330i, and it failed miserably - the lens I 'restored' became cloudy and looks much worse than when I started. A lot of effort for crap results. I think my main problem was my lenses have surface pitting that apparently went deeper than the thickness of the coating on the plastic, requiring me to sand too deep into/through the coating and into the plastic.

Bottom line is my results were very disappointing, and now I have to spend another $100+, on top of the ~$20 spent on sanding supplies, to replace the lenses with new ones.

If only I had known before starting this, I could've saved a lot of time, effort, and some cash.

Obviously, YMMV.

[siny528i]

Over the past few evenings I attempted the headlight lens restore as described here on my 2004 330i, and it failed miserably - the lens I 'restored' became cloudy and looks much worse than when I started. A lot of effort for crap results. I think my main problem was my lenses has surface pitting that apparently went deeper than the thickness of the coating on the plastic, requiring me to sand too deep into/through the coating and into the plastic.

Bottom line is my results were very disappointing, and now I have to spend another $100+, on top of the ~$20 spent on sanding supplies, to replace the lenses with new ones.

If only I had known before starting this, I could've saved a lot of time, effort, and some cash.

Obviously, YMMV.

hey quik96M3,

Thats sh****! Sorry to hear about your situation. Also thanks for the warning because my restoration is on the way, today or tomorrow.

Did you go from 400 to 2000? Did you use wet sanding?
Any pics?

PS. I am not skeptical about this task. I have a feeling that its possible to do. I polished metals before to mirror-like looks with almost same techniques. I also found a lot of tutorials before I found 540IforMe's one here. But his is important because I know now that its possible to do with E39...

[quik96M3]

Did you go from 400 to 2000? Did you use wet sanding?
Any pics?

Went from 600 to 1000 to 1500 to 2000, all with wet sanding, then finished with Meguiar's PlastX. Sorry, no pics, but I'll try to get some posted soon.

If I had any clue how thin the coating layer was, I would've stopped working with the 600 grit sooner and just left the couple of deeper pits there - the couple deepest pits weren't very noticeable, but I figured as long as I'm doing this I'm going to get all the marks out - big mistake.

Also just found out I have some ridiculously expensive lenses - the OEM's are $114 each (that's EACH, not for a pair as I originally thought) everywhere I've checked, and I've checked several on-line sources, including pelicanparts and bimmerparts. Wish I had left the whole thing alone, they weren't all that bad when I started the process. Luckily, I didn't touch the driver's side lens, but I have no option but to replace the passenger's side lens - it's completely useless now.

PS. I am not skeptical about this task. I have a feeling that its possible to do. I polished metals before to mirror-like looks with almost same techniques. I also found a lot of tutorials before I found 540IforMe's one here. But his is important because I know now that its possible to do with E39...

I also don't doubt that the process can get excellent results, as shown by others in this thread. I just wanted to let anyone interested know that the process may not be as bulletproof as it sounds here - it is also very possible to get terrible results when following the same procedure, and the level of success seems to depend on how deep the imperfections go - in other words, how far you need to sand the surface to get the imperfections out. I found out the coating layer is extremely thin - I sanded through it in a matter of a couple minutes or less when hand sanding with the 600 grit paper.

[siny528i]

Well, guys,

I just finished polishing on of my lenses and I gotta tell ya, results are outstanding. I did just one side and I did not put AE yet (waiting for my kit) but I am so far I am very happy.

I think that working with 400 is main deal because this is when you're getting rid of imperfections. I killed about 30-40 minutes with 400. Make sure that surface is smooth and free of deep scratches and dings.

Once you've done with 400, my advice to use 600 or 800, before jump to 1000, because most likely 1000 is not gonna take care of what 400 left.

I also use Ryobi Mini Buffing Kit with my Drill:
http://www.homedepot.com/h_d1/N-5yc1...atalogId=10053

And I am just wondering if we can use Orbital Buffer for this task?

Right Side (not done yet):


Left Side is done!


Sorry, I dont have day pictures, but you can see difference...

Thanks again, Mike!

[540IForMe]

You're welcome! Sad to hear it didn't work for everyone. I'd be real interested in trying to fix Quik96m3's cover to see if it could be done.

[Therealet23]

How did you make it so the angel eyes were illuminated either with the fogs, or without the fogs, but not the parking lights?

Not sure if I posted my results for my CCFL's in this thread, but if not here you go...













Thanks again, Mike!

[Camarok]

I'm assuming a series of switches and / or diodes. Pretty easy for the most part

[jamesdc4]

How did you make it so the angel eyes were illuminated either with the fogs, or without the fogs, but not the parking lights?

Looks to me like Fabs parking lights aren't lit even when he has the headlights on.

[siny528i]

Hey guys,

I just finished installing my AE with awesome results!
Mike is the Man!

On my second (passenger) lens, which turned out to be slightly clearer, I went 240 > 400 > 600 > 1000 > 1500 > 2000 > Ryobi Mini Buffing Kit - first with White Rouge, then with Meguiars PlastX, then again back to White Rouge and so on until newly charged battery on my Bosch Drill dies...



I got my AE for 35 bucks, where 30 is for shipping, from built4race (ebay). Arrived in about 3 days in brown box. I tested them - they were fine.

To make those "2 small notches on each opening for lights" I used my drill with 3/32 bit. Of course you gotta mark it first and be carefull.

That Goop is really Amazing! I will double that! Clear like a liquid glass!

Also, I wired my AEs by splicing Parking Light wires. I also made an extension, like Mike did. I used speaker wires. Gold (AE's Brown, Ground) goes to Brown. Gold-Blue (AE's Gray, Power) goes to Gray-Blue (middle wire).


Later on I am planning to buy a connector in case of future repair and easy removal.

Final result is much better than this picture:


Two things I forgot to ask though:

1. Does anyone know where to get good deal for lamin-x?
2. My new AEs are slightly cooler/brighter/blueish than my lights. is there anything i can do to match them, like installing brighter bulbs?

Than you in advance,
siny528i

[jamesdc4]

Hey guys,

I just finished installing my AE with awesome results!
Mike is the Man!

On my second (passenger) lens, which turned out to be slightly clearer, I went 240 > 400 > 600 > 1000 > 1500 > 2000 > Ryobi Mini Buffing Kit - first with White Rouge, then with Meguiars PlastX, then again back to White Rouge and so on until newly charged battery on my Bosch Drill dies...



I got my AE for 35 bucks, where 30 is for shipping, from built4race (ebay). Arrived in about 3 days in brown box. I tested them - they were fine.

To make those "2 small notches on each opening for lights" I used my drill with 3/32 bit. Of course you gotta mark it first and be carefull.

That Goop is really Amazing! I will double that! Clear like a liquid glass!

Also, I wired my AEs by splicing Parking Light wires. I also made an extension, like Mike did. I used speaker wires. Gold (AE's Brown, Ground) goes to Brown. Gold-Blue (AE's Gray, Power) goes to Gray-Blue (middle wire).


Later on I am planning to buy a connector in case of future repair and easy removal.

Final result is much better than this picture:

Looks excellent! Nice job.

[siny528i]

Looks excellent! Nice job.

Thanks jamesdc4,

Gotta protect it. Not so sure if I wanna do it all over again. Only in case if one of those AEs dies...

[STLSinger]

tried this with no luck.....the polishing anywayu. im gonna buy new ones

[siny528i]

tried this with no luck.....the polishing anywayu. im gonna buy new ones

any details of what happened?

[STLSinger]

not sure. They are just really cloudy still.

[siny528i]

not sure. They are just really cloudy still.

Did you use all types of sandpaper?
Starting with 400 (or 240 like in my case) and going 600, 1000, 1500, up to 2000?

Did you skip any of these?
What did you use and how did you do it?

Do you have a Hella lights? I dont think it has anything to do with Hella light, but still...

Just look at your lenses surface close. Do you have "scratchy" cloudness? Then either you miss one type of paper or did not sand enough?

[540IForMe]

I want anyone whose lights turned out cloudy to send me one of the covers(if they are just going to trash them). I want to see if it's operator error.

[Camarok]

is that speaker wire?

final product looks great though

[siny528i]

is that speaker wire?

final product looks great though

yes, this is exactly what I said, I used speaker wires.

[540IForMe]

Nothing wrong with speaker wire. Probably higher quality than "proper" wire you'd buy from an auto store. haha

[siny528i]

Nothing wrong with speaker wire. Probably higher quality than "proper" wire you'd buy from an auto store. haha

Thanks, I mentioned before that I want to use some kinda connectors for easy connect/disconect AE in case of repair or anything...

Do you think these Fully Insulated Quick Disconnects will do the work?
http://www.radioshack.com/product/in...ductId=2104018

Thank you in advance,
siny528i

[540IForMe]

Thanks, I mentioned before that I want to use some kinda connectors for easy connect/disconect AE in case of repair or anything...

Do you think these Fully Insulated Quick Disconnects will do the work?
http://www.radioshack.com/product/in...ductId=2104018

Thank you in advance,
siny528i

Yeah, they will work. Just make sure you cover them to keep moisture out(which would cause contamination, and eventually a poor connection).