Repairing a hole in a headlamp lens

[Otter74]

This is not for my 911, but seems better suited for here than OT, and applies to 911s, too. Plus there’s some good advice here.

I have a glass headlamp lens (on my Saab) with a hole in it - something hit it that punched a hole in it maybe a couple of mm around and took out some of the glass on the back side. These lenses are pretty unobtainable, so it’s not like I can just buy a new one. I’ve driven it as is plenty, but I’d like to repair it to protect the plating on the bowl. I figure clear silicone might be good enough, but if there’s a better idea I’d like to hear it. Headlamps are Euro H4s. Can add photo later when I have time to come back to this.

[EC900]

Sounds like a BB hole, the back side being blown out is a good indicator. Secondly this hole will likely spider from road vibrations. I would lean towards using the cracked windshield repair method that may hold up better to weather and heat. Probably be best to remove the lens to try and fix.
Another option would be overlay some of that clear stone guard paint protection material, just about anything to keep debris and moisture out.
Then start the searching process for a replacement lens.

[Otter74]

Well it was on the car for years as-is, so I’m confident it’s not getting bigger. I took it off when I found another headlamp with a better bowl that I put in, and kept this one as a spare - good thing, because last year I needed it. I have clear film to put on the headlamps but am going to do it last. Letting it be probably didn’t help the bowl but I did find another good bowl that’s on its way so I’m swapping that out and the lens is alreayd apart. What’s special abiut the windshield kits?

[boyt911sc]

Recently my Subaru Legacy’s front windshield had a big stone chip damage and was repaired by Safe Life for FREE. They come to your address on a given appointment and done in a short time. Windshields, glass windows, headlight covers, etc. are covered by your insurance. Give it a try.

Tony