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YOUR RESEARCHHeadlight Inner Lens Repair Idea - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Leading reported evidence
Repair headlight
Performed · outcome unconfirmed
No successful repair reported for this finding.
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Performed · outcome unconfirmed · Original poster
It is not noticably different than the non-repaired headlight.
Headlight Inner Lens Repair Idea - 986 Forum - The Community for Porsche Boxster & Cayman Owners
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Leading evidence: 'Repair headlight' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Repair headlight' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Discussions that performed work without a confirmed outcome
1
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Performed · outcome unconfirmed · Original poster
Here's the one I repaired next to the scortched one.
Headlight Inner Lens Repair Idea - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use with led h7 replacement bulbs
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Discussions that performed work without a confirmed outcome
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Headlight Inner Lens Repair Idea - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Repair lens by cutting out the scortched section
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Suggestion · Original poster
I decideded to attempt to repair the lens by cutting out the scortched section and replacing it with a smaller circular lens.
Headlight Inner Lens Repair Idea - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Repair lens vs
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Suggestion · Original poster
Maybe I'll pull the other one apart when I get time and compare repaired lens vs.
Headlight Inner Lens Repair Idea - 986 Forum - The Community for Porsche Boxster & Cayman Owners
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Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
20 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
986Forum: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
0 acknowledgements have no verified action link; they do not establish a repair result.
Generation: 20261026T113718Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
One of my headlights is toasted. A search for replacement lenses came up pretty much empty, except for some half lenses in Europe. I decideded to attempt to repair the lens by cutting out the scortched section and replacing it with a smaller circular lens. I didn't want to experiment on mine so I bought the cheapest used headlight I could find on ebay and went to work. Originally I thought I could find some lenticular polycarbonate sheet but struck out there too.
The headlight lens I removed from the ebay unit was scortched far worse than my original. So much that I couldn't cover it with the roughly 5-inch circular lens. I ended out cutting way outside the circle and tried to piece meal some material from the cut up lens.
Anyway, here's what I ended up with.
I purchased new lenses to my 2001 from Sierra Madre Collection (US firm):
https://************************************************** **********************************.com/Headlight-Lens-Set-986-996-99-05-p32132.html
oh-well, that was bloked, but this is their part number: SMC.631.05
I've come across those in my search. I'm guessing the attachment is the same as the standard lens, its just missing most of the lower (high beam) area. I might just consider getting them. Obviously way overpriced but then the alternative is $1000 for a new headlight, it might start to be attractive.
Theses seem to be the same - more product pictues on the website:
https://www.rosepassion.com/de/p560434-austauschsatz-innere-scheinwerferlinse-boxster-986-996-98-2001-paarweise-paar-P560434
Don't think that they solve your problem.
Much impoved over the brown spot of the old one. Focus / spread seems good. If I get a chance I'll see if I can a pic against the garage door.
I am using with LED H7 replacement bulbs. Not entirely happy with the light intensity and using them for anything other than low beams is problematic.
Overall I am happy with the repair. It is not noticably different than the non-repaired headlight. This one was intended to be practice prior to hacking into my other one and but it's good enough that I will likely leave it in and shelve my other as a spare.
Yeah, it didn't occur to me to test the light pattern without the lens but I've heard of others doing that. Maybe I'll pull the other one apart when I get time and compare repaired lens vs. no lens.
I'm not too keen on this "fix".
But, what is the exact diameter of the lenses and reflector? Maybe a pair of DOT approveed sealed beam bulps can be found in the correct dimension and mounted where the whole reflector/lens assembly sits?
R
Did you ever try calling all of the auto wrecking companies in your area. In the larger metro areas (I'm in the Chicago area) there are usually lots of them. The ones near me know their inventory and will usually let me walk the property, remove what I want and bring it up to the counter to "negotiate" a price.
Just a thought.
A while back I looked into LED projector bulb replacements, but I don't have the burnt lens problem and didn't want to bake the housings open. It's been a while and I don't have the pages saved, but something like this-
https://www.amazon.com/BraveWAY-Headlight-Cut-Off-Projector-Replacement/dp/B0C28C2VKS/ref=sr_1_5?crid=2GI93E72OOMDT&keywords=h7+led+mini+projector+headlight+bulb&qid=1697591190&sprefix=h7+mini+pr%2Caps%2C183&sr=8-5
The light pattern is controlled by the lens at the front of the assembly so the lack of the internal lens wouldn't matter. Not sure about the quality of anything on Amazon, but I think there are some good ones out there.
This is a source reference. Confirm exact model applicability in the original material.
