I have a couple of spare rear lenses that I'll experiment on first.

Apology .... Typo ... only PlastX used .... ScratchX is for paintwork.

With the outer Lens the indicator housing is part of the Lens and getting access
to the inner face of this portion of the Lens posed a challenge.
I was not keen to go the heat- gun route to remove the housing from the lens
due to previous experience with not being able to get a 100% seal on re-fitting
and constant water ingress problems.

So once again I raided the SO's Kitchen and sourced a flexible Spatula .... worked perfectly
with a Micro-fibre cloth wrapped around it and secured with Duct-Tape ...

http://i878.photobucket.com/albums/a...ps45014e1e.jpg

http://i878.photobucket.com/albums/a...psbcb665ae.jpg

All squeeky clean and ready for assembly...

http://i878.photobucket.com/albums/a...ps70ed91bf.jpg

http://i878.photobucket.com/albums/a...psf0a6699e.jpg

Assembled and back in-situ ...... stoked with the result....
Had visions of going for sobriety courses if I was forced to purchase a replacement at R 21 K
as the Frostie Fund would have had to liquidated....

http://i878.photobucket.com/albums/a...psfa66bc00.jpg

+++ PF is glass because they weren't built cheap like the later cars :p Indicator is a separate part and slots onto the main headlight.

Was just thinking has anyone rang Audi or TPS to ask how much a plastic lens is? Only reason i ask is i bought glass lenses for my PF and they were just over £25 each. Just wondering if they'll be cheaper being plastic.

I would hope that the move to Plastic was due to weight saving and not cost saving :)

I doubt that a plastic lens would be available for the PF nor a Glass lens for the
FL ..... Due to the Indicator lens variation ....

:ROFL: You reckon it was weight saving decision? The glass ones are not that heavy, it might have been done for safety over cost as i have been through 2 lenses on the front through smashing so i suppose if i drove into someone with a broken lens i could have cut them.

I wasn't suggesting a glass lens is available for a FL car just that manufacturing a glass lens must be more expensive than a plastic one.

Was just thinking if this manufacturing cost saving was passed onto the customer then it might be worth just buying 2 replacement lenses.

Just thinking 25 for real glass lenses and what 15 for plastic? Yeah right Dez

I think it's probably for ease/cost of manufacturing.
Plastics technology has evolved a lot in recent years with (in my opinion) some quite bizarre and complex lights as a result.
Just because you can do it doesn't mean you should.....:tuttut:

A Google search revealed ....

The use of plastic in headlamp applications enables automakers to reduce weight without sacrificing optical performance while increasing resistance to breakage.

Plastic offers the advantage of being an inherently light material that can be easily made in thin sections and stepped shapes, reducing weight and the possibility of breakage “without sacrificing optical performance.

Plastic’s versatility allows auto headlights to incorporate designs that can increase highway safety, such as high-tech focusing designs in the lenses.

Polycarbonate, sometimes used as a bullet-resistant glazing on other applications, has about 200 times the impact strength of glass. This strong, stiff, transparent thermoplastic can maintain rigidity up to 140° C (284° F) and toughness at -20° C (-4° F).

A look at Elsaweb showed that there is a kit for repairing the headlight unit clips if they break during removal to save replacing the whole unit. Obviously a known problem.

See http://elsaweb.spaghetticoder.org/do...-EA/20839180/2

Can we add this thread to the repair sticky? Came across it looking for previous experience of stripping headlights and thought it's really useful :)