I do headlamp restorations on a regular basis. The best process I have come up with is very simple.
*thoroughly clean each lens
*tape off areas around the lens to avoid accidents
*Sand the lenses with 500, 800, 1000, and 3000 grit sandpaper cleaning the lense before going to the next grit.
*Polish
*Apply sealer. I use the Wynns kits just for the sealer. Its $20 for a kit and there's enough sealer for 6-8 lenses.
I have the mini sander and polisher so I can knock them out pretty quick but you can still do them by hand with great results in less than a couple of hours.
