We've been working on a partial headlight restoration process for some time. Starting to get good results. The problem has always been feathering between the old and the new and potential adhesion problems between new coating and old.
Our current approach is to apply a chemical strip that will remove all of the damaged coating and just a tiny amount of good coating, then polish the entire headlight at 3000-4000 grit, then apply a water based new coating across the entire headlight. So far adhesion is very good and can't be removed with 3500 psi water pressure like solvent based can.
Will take at least 2 coats, but cure time is less than 5 minutes between coats.
Will be posting video of latest test restoration next week.
Stay tuned.
ray6