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Old 09-11-2013, 05:35 PM   #1
jimmy_jammy
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Talking Smart Roadster Coupe - Rear plastic window restoration

It seems to be a common problem with Smart roadster coupes and the older Smart ForTwo that the rear side plastic windows over the years deteriorate due to a layer of lacquer on top of the window reacting in sunlight, flexing and bending and many other factors.
The cheapest I found these windows is £184....each!

I made the decision to start a restoration on each of mine and went ahead and purchased a rotary polisher (EP801), polishing and finishing pads (3M), 1200 & 1000 grit sandpaper.

First off... If you do not have a rotary polisher, don't even attempt the following. (I tried by hand - its impossible). Also make sure you have a lot of spare time to do this and lot of patience.

This is the daunting task ahead of me, they are rough to the touch, look terrible and it is difficult to see out of them!

















To start with, get yourself some sandpaper and a sanding block.
I have pictured 1200 grit here but start with 1000 grit.



Clean your windows throughly so you don't rub more deep scratches into them and get some masking around your window so you don't sand your paintwork off!



Once you have got this far... there is no turning back



Here you can see I have broke through the layer of lacquer we need to remove, to get this far took about 20 minutes. When you are rubbing with the sanding block make sure you brush the sandpaper regular as small clumps can build up which will cause problems.
Keep checking how worn the sandpaper is so you can work smarter and use every last bit of sandpaper up before you replace it. I found I had to remove the sandpaper sometimes to get the most out of the edges and for the tricker corner of the window.



around 45-60 min of sanding will get you about this far...
It is pretty clear where the layer has come off and where you have already sanded.



A reminder of how bad the top layer is



a Little trickier to see on the clear part where has already been sanded, but get it in the right light and its good.





After a long long time, I'm on the final stretch!
Once this far go round all the edges and make sure nothing has been missed, remember the better the preparation the better the finish will be.



Once the top layer is completely removed, go over the whole window for about 20 minutes with 1200 grit wet. This will make it a bit easier once at the polishing stage. I could have gone up to 2000 grit but was lazy and didn't buy any!



After a wet sand it should look like this... worrying!





A view from the inside, I have masked up a section so its easier to work and concentrate on a section at a time.





Weapon of choice



10 minutes of polishing





Still a long way to go, and this bit is the hardest if you want it closer to perfection.



After a lot more polishing



Got to love them 50/50 shots





After a few days of work, cleaning with DoDo juice lime prime lite before the finishing pad and some Zymol cleaner wax this is the finished product












The final finish I achieved is probably about 85% corrected. There are still a fair few light swirls I want to remove and find a UV protectant wax to finish with. But from where It came from



To where it is now



I am happy and £300 better off when you include postage of new windows and minus the cost of my rotary polisher - courtesy of CleanYourCar.

Thanks for reading and I hope this helps someone!
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Old 09-11-2013, 05:39 PM   #2
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Nice work. Is that by any chance a Brabus?....
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Old 09-11-2013, 05:42 PM   #3
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Wow great transformation!
Appears to me that it's the same kind of process as restoring headlights.
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Old 09-11-2013, 05:58 PM   #4
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Nice work. Is that by any chance a Brabus?....
Yes it is

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Wow great transformation!
Appears to me that it's the same kind of process as restoring headlights.
I looked into this, and got some of my ideas from that. But the windows were in a very poor state, not just like a discoloured headlight but had a very rough and textured surface which had to be removed.
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Old 09-11-2013, 11:01 PM   #5
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Well done! Great work!
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Old 09-11-2013, 11:10 PM   #6
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Excellent work, what a turnaround
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Old 09-11-2013, 11:16 PM   #7
AGRE
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Great results
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Old 09-11-2013, 11:54 PM   #8
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Well done! Great work!
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Excellent work, what a turnaround
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Great results
Thanks!
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Old 10-11-2013, 01:23 AM   #9
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Great work I would be tempted now you have done so much work to go to 2000 and 3000 sand paper to make it easier to get sand marks out for perfect finish

Also if you want to go the whole hog on protection order some of this over as dont think you can get it in the U.K yet

http://www.autogeek.net/optimum-opti...t-coating.html
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Old 10-11-2013, 01:57 PM   #10
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What a bloody awesome turnaround.

I did the same ´man maths´calculation the first time I did headlights with sandpaper and a DA polisher.

The car would have failed its CT (France) in the state the lights were in, so instead of €360 for a new pair of lights, I got the CyC DAS-6 set instead!

Quids (or rather, euros) in!
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