Roadster headlights live a hard life. Parked right at the nose of the car, they take every hit from UV, heat, road debris, and weather. Add a marginal factory clear coat that breaks down over time, and those once-crisp lenses can start to look tired and cloudy.
When these cars were new, you could buy fresh assemblies from your local Tesla Service Center. Those days are over — complete Roadster headlights are now out of production, and good used sets are scarce. The good news: the originals are completely rebuildable, and worth saving.
Left alone, this kind of damage drags down an otherwise beautiful Roadster. The upside: almost all of it is reversible with the right process and materials.
| Stage | What it includes | Best for |
|---|---|---|
| Stage 1 Basic Headlight Rebuild |
Strips failed clear coat, de-oxidizes and polishes lenses, applies new UV-resistant clear and PPF, repairs the parking light lens and upgrades it to LED conversion, install new foam weather-stripping and rubber caps, and reseal the assembly. | Cars with cosmetic issues (peeling, hazy lenses, minor fogging) where the owner wants OEM appearance restored and protected. |
| Stage 2 Full Restore & LED Upgrade |
Includes everything in Stage 1 plus full low- and high-beam LED conversion, updated load circuitry and Switchpack resistors (1.5 Series), and additional work for heavily aged or moisture-damaged headlights. Finished lenses receive PPF and a ceramic-coated, high-gloss surface. | Owners who want the best possible lighting performance and longevity while keeping the original Roadster headlight housings. |
Pricing: Stage 1 starts at $615 / pair, Stage 2 at $1,295 / pair (pricing shown above is for the pair of headlights).
If you are unsure which stage is right for your Roadster, we can review photos and help you choose the best option.
$615 / pair — This basic level of headlight repair/rebuild resolves the most common issues, including original design problems such as using a hot incandescent bulb in the parking light socket which eventually melts the mounting tabs and lets the lens roll around inside the headlight. (This service is performed in our Phoenix location Tesla Service Center)
Parking Light Bulb Upgrade
The Roadster originally came with incandescent bulbs in a tight enclosed pocket. Over time, heat discolors the lens, weakens the mounting tabs, and the lens breaks free and rolls around inside the headlight. We replace the hot incandescent bulb with a much cooler, long-life LED and secure the lens so it stays put.
De-Oxidize and Clearcoat Lens
As the car ages the original clear coat is attacked by UV and environmental fallout. We strip the failed coating, de-oxidize and polish the lenses, then apply a Euro-spec UV-resistant two-part clear for long-term protection, followed by a layer of UV resistant Paint Protection Film (PPF) for additional gloss, protection, and durability.
New Foam Weather-stripping
The foam that seals the gap between headlight and fender compresses, hardens, and shrinks over time, allowing water and debris to enter. We remove the old material and install high-quality new foam weather-stripping to restore a clean, tight seal.
New Rubber Caps and Seals
Aging rubber bulb caps harden, crack, and lose their ability to keep out moisture and dust. We replace these caps with new rubber pieces and secure them with stainless-steel clamps to maintain a reliable seal.
Headlight Assembly Sealed
We remove the lens, clean and polish contact surfaces, then re-attach it to the housing with a modern urethane sealant. All ports and openings that can draw in moisture are sealed to help prevent fogging and contamination in the future.
PPF Coating on LensAs a final step, we apply a UV-resistant PPF layer to the headlight lenses for long-term protection, available in both clear and tinted versions. The LED conversion is plenty bright to shine through the tint, and the finished look gives the car a seriously striking presence.
$1295 / pair — Includes everything in Stage 1 plus a complete LED conversion of low and high beams and additional work for cars with heavily aged headlights. (This service is performed in our Phoenix location Tesla Service Center)
This level is designed to fully modernize the lighting system while retaining the original Roadster headlight housings. Carefully selected load resistors are replaced in the Switchpack to eliminate burned out bulb alerts.
Replace Low and Hi Beam Bulbs with LEDs
Lighting technology has advanced significantly since the Roadster was launched. We replace the stock low and high beam incandescent/halogen bulbs with modern LED units that run cooler, draw less power, and provide a much sharper, whiter light output. Matching load circuitry is used so the car’s control systems see a proper electrical load. This final step completes the restoration of stock Roadster headlights and brings them up to modern standards while preserving the original look of the car.
