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Discussion Starter #1
I did a search but could not find much, has anyone had any luck restoring Carello headlights?

They are in good condition but dirty inside so need a good clean and polish, is it a bad idea to attempt to separate the lens myself or is this best left to a specialist?
 

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Headlight silvering will not respond to 'polishing'. You'll just be left with permanent swirling marks in the reflector bowl. Leave this one to a pro.

p.s. Nitromors paint stripper has been known to soften the adhesive between the bowl and the lens.
 

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well , done it many times before with great results, however, with one condition...reflector bowl was good more than average. If your reflector is rusty , just forget it and get a new one.
Now, how I done it: buy some liters of distilled water and liquid soap (take it from your wife if you have one). Take of carefully the behind bits where bulb located and supported. so, you have now one hole with some cm of diameter no hand can be work there only one finger but that finger cant do the job, too, especially for the inside lens.In the very first stage of cleaning you can use normal water, do anything you like with the water use pressing water with the soap, use plenty plenty of water! While doing this, put inside your preffered finger and clean the muddy reflection bowl as good and as deep you can. USE only your finger and nothing else with the bowl. However, you must be lucky enough to clean the deepest part of the bowl and the lens , means you must have a very long finger, maybe! If you not, here is the trick: take a wood stick like a pencil and use -or make- its one end flat and NOT like a knife of course. Also get a clean old and white T shirt made of COTTON only and cut some small pieces of it. Use these pieces to cover the end of your pencil and pass it threw the hole. Your headlight is still wet, so your pieces can be wet, too, no problem, if not better. It is easy now to use your pencil/ cotton pieces as a combo with some force to the inside lense , you can see from the front what exactly you are doing with your tool! Human hand has extremely specs for doing such jobs and you will be amazed from the result. When you are feeling that you cant do any more, stop and deep the headlight in a big bowl where the clean distilled water is wating and clean again WITHOUT any soap now. Clean only by mouving the inside water and not with any other thing or finger.Clean very well and then go again to your ...kitchen. Take with you a piece of wood which can be used as a base to stay your headlight(s) on. Heat up your oven to 80-90 celcious with the fan also. Slide inside the supporting wood and your headlight with the lense facing the wood so the hole will be on the upper side. Close the oven's door and leave it there for 20-30 minutes. Then turn of the oven,open the door and leave the headlight to take again the ambient temperature. Then check the final result of your work.
Of course, prior to this procedure, it might be a good idea to clean/sand the outside bowl so to paint it again after. At the very final stage you can ckeck what is the condition of the lense to bowl sealing. Carello, usually used a hard white material while Elna a black material. there is always a chance this seal will be found cracked or even not so correct fitted from the factory... No panic. Get a small drill like a dremel and use the proper cutting head and make -WITH VERY CARE PLEASE- this yellow material again WHITE! Then use a high temperature clear varnish with a tinny brush to cover all the sealing material from the glass till the bowl , all the way and peripherically. If you make any excess on the glass with the brush , you can easilly taking off later. You can also spray or brush with the clear varnish the rear bowl but be carefull not to paint also the front glass.
As mentioned before, I've done it many many times before with really amazing results, in some cases the result was better even comparing with a new NOS...Sorry, dont have any photos with me , as I'm in vacations
 

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Oh...in case you dont have the skills and the very special tools for the job , dont try to separate the glass from the bowl! You will be end up with a broken glass...
 

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Discussion Starter #5
Hey alfaroad, thanks for taking the time to share your technique! I might give this a try myself. One question, why do you use the oven? Is this simply to dry the unit or does it help evaporate residue?
 

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Pressing air is also a good option. However, I found that the best drying method is the oven and the ...sun (got plenty down here). With the oven metal parts also being heated so there is not any chance to have any wet inside. If you dont feel so happy with the oven, you can try also the hair dryer, works also perfectly. I remember in some headlights I used the dryer with the same results but needed to be for many minutes shooting the hole to get the hot air in...
 
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