Refurbished Headlights

[RubyRod]

I just finished refurbishing my headlights. Tom at WinnipegHID.ca replaced the Turn Signal lenses with new lenses. Replaced all the incandescent bulbs with LEDs. Provided Load Resistors and wiring. I mounted the Load Resistors on the bumper bar under the Headlights. Tom did some polishing of the main lenses but there were still some imperfections. I polished them a lot more. Then I had Paint Protection Film applied over the headlight and fog lamp lenses. They look pretty good. The main lenses have some scratches and micro-fissures but overall they look a lot better than when I started. Hopefully the LEDs and Protective Films will prevent further deterioration of the lenses.

 

[joefish]

What was the cost to refurbish?

 

[RubyRod]

What was the cost to refurbish?

It was excessive. I didn't start out intending to refurb the Headlights. I had to pull the Headlights in order to pull the front fenders. Both fenders need some body work and I wanted to pull the fenders to see what I was up against. Anyway ... When I pulled the passenger Headlight I found that the housing was damaged beyond repair. There was a long crack that ran between all 3 mounting studs. One of the studs had already completely separated from the housing. One of the other 2 studs had some missing plastic adjacent to it and it would separate completely from the housing relatively soon. So I started shopping for headlights. While I was shopping I stumbled over the WinnipegHID.ca webpage offering replacement Turn Signal Lenses. Since mine were in pretty sad shape and most of the Turn Signal Lenses in the replacement Headlight Assemblies I could afford ... well almost afford ... were in no better shape than mine I inquired about them. Since I had to replace a Headlight anyway I figured now was the time to address it. Tom @ WinnipegHID claimed he could replace them for me. I just had to pack & ship them. Not as easy as it sounds. I told him I was shopping for a replace a Headlight Assembly because one of my housings was severely damaged. We emailed back & forth and found that he had a replacement Housing to replace my damaged one. The cost to replace the Turn Signal Lenses, upgrade to LEDs, & replace damaged housing was less than a single replacement Headlight Assembly in "fair" condition. So I decided to have Tom refurb the Headlights.

The cost for mine, including shipping back & forth, upgrades to LEDs, mounting the LED load resistors, the replacement Housing, polishing the Headlight & Fog Lamp lenses, having a crack at the alignment pin on the replacement Housing welded, and having protective films applied was close to $2K. It's pricey.

Tom quotes $1200 to replace the Turn Signal Lenses & upgrade to LEDs. It doesn't include shipping to him or import fees when he ships them back. It cost me $150 for shipping and another $50ish in packing materials. It also cost me $50 in import fee when he sent them back. (Note that the Trump tariff threats may make shipping the Headlights back & forth to Canada for refurb may be a LOT more expensive in a few months.) Tom buffs out the main Headlight lenses after he finishes the replacements. My main lenses still had some imperfections in them and so I decided to try and polish them out on my own. They came out marginally better but it's a lot of extra work. I also had protection films applied. I was going to use a ceramic coating kit for Headlights but Tom recommended protective films. After looking into it the films seem like the better choice. Especially after putting so much effort into them. And since there are no new replacement units available it seems like prudent insurance. Here's hoping.

 

[joefish]

Wow! 2k is heavy for the headlights. Although you can't find any without the dreaded burnt lenses.
They do look real good.

 

[Fireduck69]

One of the best things I did back in 2013 when I got my XLR was to put film on the headlights.

To get around the import fees, you have to declare them to customs before you ship them out of the country. No import fees on returns just imports.

 

[NYCDGS]

Dose anyone know who can make the outside plastic to go over our lights, the plastic cracked but all the lights work, just need to replace the cover for the lights, I can't believe no one can make them.

 

[RubyRod]

There are some aftermarket plastic headlight lens covers available for some model cars but I haven't see one for the XLRs. You may want to do a web search and see if you can find a few sources for them and see if anyone makes one. It will probably take some emails/phone calls etc to find out for sure. If you are unable to find a plastic cover your only other choices are a replacement Headlight Assembly or to live with the cracks/damage to your lenses. At this time no one makes a replacement main lens.

If the main lenses are only cracked and no lens material is missing find a local shop that specializes in Paint Protection Films and stop in and discuss applying it to your Headlight lenses. I had XPEL paint protection films applied to my Headlights and it should prevent any further deterioration of the lenses. At least for a few years.

 

[mickeytee]

Theres a guy making them on another forum or somewhere i read. But until i see them ill hold from endorsement. In the last 4-5 years id say theres been at least a dozen people claiming to make them. no one does. It a difficult bonding process to secure the outer lens. Its also a very limited market and if actually out there they would be 500-800$ good news is there is way more supply of used than needed so make an offer on some. You nay be surprised. 04-05 have bad lens material. Stay away from them. A flooded light should be bought for 4-500 if you can find someone to change it over

 

[NYCDGS]

There are some aftermarket plastic headlight lens covers available for some model cars but I haven't see one for the XLRs. You may want to do a web search and see if you can find a few sources for them and see if anyone makes one. It will probably take some emails/phone calls etc to find out for sure. If you are unable to find a plastic cover your only other choices are a replacement Headlight Assembly or to live with the cracks/damage to your lenses. At this time no one makes a replacement main lens.

If the main lenses are only cracked and no lens material is missing find a local shop that specializes in Paint Protection Films and stop in and discuss applying it to your Headlight lenses. I had XPEL paint protection films applied to my Headlights and it should prevent any further deterioration of the lenses. At least for a few years.

All lights work perfect, it's just the plastic that goes over it, see picture.

 

[mickeytee]

It would be a good candidate for a lens if anyone made them. You did not list the year of your car. Id watch for a parts light on ebay like i said that has all the electronics corroded and find someone to swap the lens.

 

[NYCDGS]

It would be a good candidate for a lens if anyone made them. You did not list the year of your car. Id watch for a parts light on ebay like i said that has all the electronics corroded and find someone to swap the lens.

Thanks it's an 06 Base

 

[mickeytee]

Then stay away from 04-05 lens unless you see one really cheap. They all interchange but 06 started a better material. They just did not bond them well and 100s blew off. Thats why we have no spares. They all got used up on warranty when they were newer

 

[RubyRod]

All lights work perfect, it's just the plastic that goes over it, see picture.

Wow! That's a little more than just a few cracks. If the lamps all work now that's a good thing. But I suspect that over time they will stop working. Moisture will get into the electrical connections and cause plenty of corrosion. Not a lot of fun. I would definitely search for a replacement assembly but it's going to be pricey. If the housing is in good shape contact Tom at WinnipegHID.ca and ask him if he has any lenses he could swap onto your housing. It's worth a shot anyway. It'll be pricey too but it might be worth considering.

I wish you well.