Great job and write up Adrian there's something very satisfying about taking somethg like that apart and refurbing it, the results are so much better!
I'll add this to the section sticky when I'm back on my laptop +++

Well I pulled the drivers side light out in the week - started working on it last night and polished the outer lens while it was still assembled on the body of the light.

This morning I've got it stripped down and so far it's not going so well! The clip holding the outer lens near the indicator was holding onto thin air due to the lens end of things having parted company at some point....

Rung TPS (the outer lens has a couple of big chips in it anyway) and there's no replacement lens in the country, so I'm looking at waiting for stock from Germany in a week to 10 days :( so now the car is off the road until I can get that.

Also found on dismantling that the trim under the headlight has previously been gorilla'd off the car and 1 of the 2 mounting barbs was snapped clean off. It was still sitting in the rubber grommet so there's a small chance I might be able to glue it back in place! Bit annoyed at that....

I'm not sure whether to admit defeat today or push my luck and remove the inner reflector cover. The way I'm going there's every chance one of the 4 clips will shear off!

I've also found a rubber grommet floating about in the headlight body which I've no idea where it came from. It's possible it's nothing to do with the headlight I guess. Will post a pic of it later and see if anyone recognises it.

Time for coffee and a think

I've got various bits of headlight in a box in the garage, including an outer lens IIRC.

I'll have a look at the weekend and let you know. In the meantime, if you can let me have a list (with photos preferably) of the bits you need, I'll see what I can find.

Cheers for the offer - I've ordered a new lens which will take about a week to arrive from Germany, allegedly. Cost was just under £75

This is what's broken off the original:

http://i5.photobucket.com/albums/y18...ps3idkd01h.jpg

http://i5.photobucket.com/albums/y18...psniwrzhzm.jpg

and this dropped out of the headlight when I took the lens off! Not even sure it's from the headlight!

http://i5.photobucket.com/albums/y18...pst60lmdln.jpg

Condition is much the same as the other side, although I can't help thinking that the exterior condition of this one suggests the nearside one has been replaced at some point

http://i5.photobucket.com/albums/y18...psqvbnsbfb.jpg

http://i5.photobucket.com/albums/y18...pswaag5rhm.jpg

http://i5.photobucket.com/albums/y18...psyu1w0b1i.jpg

Inner reflector has come off OK again (phew!)

http://i5.photobucket.com/albums/y18...psifs2q0zx.jpg

http://i5.photobucket.com/albums/y18...psu7uddbom.jpg

http://i5.photobucket.com/albums/y18...psxuywxfdb.jpg

The hole for the sidelight bulb was a fair bit smaller than the other side, so required more material removing to allow the LED sidelight bulb to fit. That's all done now (no pics) but think I'll leave any further cleaning until I have the new lens to fit. Would rather not spend time cleaning the reflector up only for it to get dusty again!

Finally finished! Well nearly.....still got to repair the broken plastic barb on the trim under the headlight, but I'll do that after writing this!

I collected my new driver's side lens yesterday, so this morning was all about cleaning the reflectors, replacing the outer lens with new gasket and getting the bulbs fitted, then back in the car and off down to my local indy who then checked and adjusted the beam alignment for me (drivers side was low but otherwise all good)

New lens fitted and reassembly on the bench done - the box for the lens was dated January '14 so pretty recent stock, so they're still making some stuff!

http://i5.photobucket.com/albums/y18...psyhjrrqct.jpg

Both LED sidelights now fitted

http://i5.photobucket.com/albums/y18...psqpq2ol7j.jpg

and with the headlights on you get a nice white light, rather than a tinge of yellow courtesy of the old school sidelights!

http://i5.photobucket.com/albums/y18...pstsvoic59.jpg

I'll see what it's like to drive at night (probably tonight as I'm off to Surbiton karting) and I might order some new xenons - although these are 4 years old I know they were old stock from when the cars were current, so I think more modern bulbs will give a better light output.

Haha Sergey thats a new one!
Good job Adrian. That's the first time I've thought a set of xenon pluses actually look good on a d2 because the little piddly sidelights don't ruin it!
One of the reasons I went for Xenons rather than Xenon Plus on mine was for that very reason!

Thanks Sergey - that's brilliant! May have to take you up on the offer as I do glance at my sunroof panel when I'm up in the loft and think it'd be a lot better in the car!

Neil - they do make a big difference, but it's a risky job to do if you do manage to break something that's part of the main headlight assembly. I'm convinced my driver's headlight is as old as the car but the passenger side one is newer - it has a lot less wear and tear, less rusty clips, better condition painted plastic on the inner reflector etc etc.

I followed up the headlight refurb with changing the offside outer rear tail light as well! It's had a crack in it since I bought the car and I came across one recently for £20 which had only had a couple of years use, at most. Getting quite good at boot trim removal now lol

What did you use to clean this lens?

From memory just detailing spray and a micro fibre cloth. Be careful attacking it with anything stronger, as the ‘chrome’ finish is VERY fragile to chemicals (avoid getting any on it and mask off for preference - just dry wipe the chrome finish)