Headlight Restoration
& Wet Sanding
Abrasive sanding of polycarbonate · Polishing · UV sealant
Issued April 2026 · Next review April 2027
At a glance
- Task / activity
- Headlight Restoration & Wet Sanding
- Location
- Workshop with extraction or open ventilation
- Personnel required
- 1 detailer
- Estimated duration
- 45–90 min per pair
- Prerequisite training
- Wet sanding technique sign-off · Site induction · Electrical safety
What is this?
Restoring oxidised polycarbonate headlight lenses by progressive wet sanding (400–3000 grit), polishing, and applying a UV-resistant sealant.
Performed by 1 detailer in 45–90 min per pair. Workshop with extraction or bay door open.
What could hurt you?
- • Polycarbonate dust inhalation — sanding slurry produces respirable particulate.
- • Skin sensitisation from urethane / acrylic UV sealant carrier (cumulative).
- • Electric shock from DA polisher in wet sanding conditions.
- • Spatter and slurry to eyes during polishing stages.
Mandatory PPE
Sealed safety goggles, nitrile gloves, P2 half-face respirator, waterproof shirt / apron, and hearing protection if DA exceeds 85 dB(A).
Polycarbonate dust is fine and respirable — keep the surface lubricated to suppress.
STOP — Suppress dust at source
Always keep the sanding surface wet. Polycarbonate slurry suppresses respirable particulate; dry sanding releases it. If the lens dries during sanding, stop and re-wet before continuing. P2 respirator is the second line of defence — wet suppression is the first.
Mandatory PPE
-
Sealed safety goggles
AS/NZS 1337.1 — wet sanding mist + abrasive particulate. Sealed goggles, not open glasses.
-
Nitrile gloves
EN ISO 374 — protects from slurry contact and UV sealant skin sensitisation.
-
Half-face P2 respirator
AS/NZS 1716 — polycarbonate dust is fine and respirable. P2+OV when applying solvent-carrier UV sealant.
-
Apron / waterproof shirt
Wet sanding produces dirty slurry — clothing protection and easier clean-up.
-
Hearing protection
AS/NZS 1270 — required if DA polisher use exceeds 85 dB(A).
Procedure
- 1
Mask surrounding paint, trim and badges.
Hazards
- •Paint damage from oversand
Controls
- •Two layers of tape on vulnerable edges; LED light to inspect coverage
- 2
Wet sand starting at coarsest needed grit, stepping up.
Hazards
- ⚠Polycarbonate dust inhalation (slurry)
- •Skin contact with slurry
- •Slip on water runoff
Controls
- ✓Keep surface lubricated to suppress dust — re-wet immediately if drying
- •Respirator + sealed goggles
- •Towel down floor regularly; mop slips immediately
- 3
Inspect under LED; repeat / refine grits.
Hazards
- •Eye strain
- •Repetitive motion
Controls
- •Frequent micro-breaks
- •Vary hands and posture
- 4
Polish with compound on DA / wool pad.
Hazards
- •Spatter to face / eyes from sling-off
- •Heat build-up cracking the lens
- •Vibration (HAVS) from sustained polishing
Controls
- •Sealed goggles
- •Speed control; do not dwell on one spot
- •Limit continuous tool time; switch hands; take micro-breaks
- 5
Apply UV-resistant sealant per manufacturer.
Hazards
- •Solvent inhalation (often urethane / acrylic carrier)
- ⚠Skin sensitisation (cumulative — repeated exposure compounds risk)
Controls
- •Ventilate; respirator on (P2+OV)
- •Gloves; do not touch lens after coating; bin applicator immediately
- 6
Cure (UV or air per product); remove masking; inspect.
Hazards
- •UV lamp eye damage if curing lamp used
Controls
- •UV-rated goggles or face shield; never look at lamp
- •Signage on workbench during cure
- 7
Dispose of slurry, used paper, contaminated water.
Hazards
- ⚠Polycarbonate slurry into stormwater
- •Sharp paper edges
Controls
- ✓Catch slurry in tray; bin with general waste — never to drain
- •Bag used paper