The headlight lenses on my '86 240(204K) are yellowed and chipped and no longer transmit light very well. Can I purchase just the lenses or do I need a whole new assembly. In either case, what is the best source?

If you decide to replace them because of the chips, you'll probably find that the dealer price is extremely high. Check Ebay for good used headlights. I've seen good clear ones sell for around $50-$100.

I had great success polishing these lenses .Start with 220 grit on a random orbital sander and work your way up to 400 grit drylube paper.Use a lambs wool buffing pad on a 7" buffer( as apposed to a grinder)with the proper automotive/boat polishing compound.

You'll be amazed at how they come back......PC

Great advice, a couple of questions. Random orbital sander as in a Makita type hand held woodworkers tool? 7" buffer like a chamberlain car buffer?

I used Novus 1-2-3 Plastic polishing system. You can get a kit at NAPA I think, its worth getting some because you can use it for a lot of diferent things around the house . I would use some 1000 grit wet or dry with baby oil as a lube on the outside. The inside use a wool buffing pad with the Novus, mine look brand new. New ones cost 160.00 EACH.

THe polisher I use looks like a right angle grinder but it runs much slower .It is quite agressive when used on auto paint.I believe the unit your refering to is more for waxing.The electric sander I use is a porter cable.It is a true DA ,that is,a dual action sander.A lot of these sanders just seem to vibrate in ones hands without doing much work.Particularly mainland Chinese sanders.Try having a conversation with an auto body supply house.........PC