> What you are trying to make already exists=2E I work for a Honda dealer a=
> nd we used to sell an adhesive backed=2C soft=2C clear headlight cover ca=
> lled=3B Impact Headlight Savers=2E We still have a few old sets instock=2C=
>  the only markings on them is a mailing address=3A
>
> GPMA
> P O Box 4643
> Missoula=2C MT 59806
>
> They may no longer exist=2C not sure as we have not ordered them in years=
> =2C but I have seen a similar product advertised within the last six mont=
> hs=2E If you cannot find any specifically to fit your van=2C just order s=
> ome for a car with larger lights and cut them to fit=2E

You can buy these for a Vanagon.  I did--from Griot's Garage catalog:
http://www.griotsgarage.com/catalog.jsp?&SKU=10232
They do come from Montana--drop-shipped.
I had them on my old 911 for years and after getting the
Syncro and hearing about the cost of new lenses, I put them on it.
They fit perfectly--except that the L/R for the one of the two were
reversed.  I emailed the outfit in Montana and alerted them.  That
was a couple of years ago. It was obvious enough to me when getting
ready to install them.

You can also buy sheets 10x16 or 20x16:
http://www.griotsgarage.com/catalog.jsp?&SKU=10227
These are 23 mil thickness; the custom cut are 40 mil.

The trick is the glue which doesn't yellow so they stay clear for
years as my 911 showed.  When I got my '88 Carrera they were one
of the first things I put on them; $350 replacement lenses!  For
the Vanagon and the 911, careful installation was enough; I didn't
need the squeege.  Maybe I'd use it for the thinner stuff.

                                Richard A. Jones
                                Boulder, Colorado