What you are trying to make already exists. I work for a Honda dealer and we used to sell an adhesive backed, soft, clear headlight cover called; Impact Headlight Savers. We still have a few old sets instock, the only markings on them is a mailing address:

GPMA
P O Box 4643
Missoula, MT 59806

They may no longer exist, not sure as we have not ordered them in years, but I have seen a similar product advertised within the last six months. If you cannot find any specifically to fit your van, just order some for a car with larger lights and cut them to fit.

Mark in AK (the broken headlight capitol of the US)
87 Westy Syncro

Happy Friday to all,

2 weeks ago I had a rock or object crack my front right small headlight
glass. This got me thinking about ways to protect it. I know they make Lexan
covers but I figured that for the same $50 dollars I could just go to the
plastic store and pickup some thick clear acrylic sheets, cut it to size to
cover both the low and high beam glass.

I am not sure how to adhere it to the glass, I guess I can figure someway to
adhere it to the body grill. Maybe Clear Silicon, or a possibly 2 mounting
screws. I am open to ideas. I just can�t see purchasing those lexan covers
when I can make it myself. Anyone see any draw backs to this idea?

Anyone know how those Lexan Lens covers adhere to the Glass?

Thanks,

Robert
NYC
89 Carat Auto