teslamotorclub: Optimized Optics: High Performance Headlights, Improved Output & Improved Aesthetics part 1

Optimized Optics: High Performance Headlights, Improved Output & Improved Aesthetics

Greetings,

First post here so I better make it a good one! I like to modify headlights, doing so brings be a lot of enjoyment because with a well executed build I am able to improve function and performance at the same time. My main goal once I get inside a headlight it to optimize the lighting performance first and foremost, there are many headlight gurus who will open up a headlight and just paint, add LEDs, or do a clear lense swap, this is great and all but it pains me when all that "custom" work is done but the lighting performance, for the most part, is untouched (clear lens swap is a step in the right direction), there is so much to gain when a high quality projector is tuned and installed.

I recently got my hand on a set of Tesla Model S headlights to do some testing and experimenting. I am a huge fan of the overall design of the headlamps and appreciate the simple layout: LED DRL, LED turn signal, and Bi-Xenon projector ...awesome, all you need IMO. Since the DRL and signal have their respective diffusers and there is no ugly high-beam bowl, you can paint the housing as you wish with no deterioration in performance which I very much appreciate.

From what I gather, Tesla Model S & Roadster owners are underwhelmed with the performance of their headlights (especially the roadster) so I was eager to get the headlight open and see what components Tesla used. The ballasts are 35w and bulbs D1S, both Osram. The projector has no markings on it but out of the popular projector brands on the market: Bosch, Hella, Koito, Stanley, and Valeo; it resembles a Valeo unit but I wouldn't be surprised if Tesla had their own projector produced, all I know is that is isn't that good. Considering how itty-bitty the reflector bowl is, the performance isn't bad. Still, compared to the quality projectors that Koito and Stanley produce the Tesla is a far cry from the same level of performance, more on this below.

Anyway, I am wrapping up a retrofit on these headlights and I wanted to share. The oem Tesla Bi-Xenon projector was replaced with a bi-xenon projector from a Lexus RX350, this projector received a clear-lens upgrade as well as some tuning to yield a very sharp cutoff with a little bit of color (that blue/purple color along the cut-off which is a byproduct of light intensity and focused optics). The housings were stripped of chrome, prepped, and painted with a semi-gloss high-temp paint. I am very pleased with the end results, the headlights look bad-ass and there is plenty of performance to back up the looks!

Cheers,
Evan

Before, stock ...lol stock...

After

Before

After

THE PROCESS
Lens Removed

Heavy Duty LED setup

Oem Tesla projector

Notice the fresnel lens

Such a tiny bowl!

Here is a comparison to a Honda S2000 projector, one of the highest regarded projectors around, bowl volume usually translates to a wider beam output and/or better light output in general.

Internal board, pretty elaborate compared to other headlights I have seen. I am assuming the Tesla has a light control module located elsewhere in the car. For example, my car, a 2008 BMW 535xi wagon has adaptive HID headlamps and I have a control module in my car and each headlight has it's own small module, they are about 1.5"x1.5" and very small relative to this huge board. I also found it interesting that the headlights I am working on do not had an AFS/adaptive feature. Anyway, not sure why this board is so big!

LEFT: Lexus RX350 RIGHT: Model S

STI-R clear lens installed

Comparison

Tesla ballast is designed for a D1S ignitor/bulb and the Lexus takes a D2S bulb. I purchased some D1S-D2S ignitor/adapters which will allow me to retain the oem Osram ballast with the D2S bulbs. The Osram ballasts are good, not great but good, I would normally use a better ballast but with the design of the headlight if the ballast is removed there is a huge hole on the bottom of the housing so for the sake of simplicity I will leave it in place.

Projector bracket

I trimmed the bottom to fit the Lexus solenoid

I was able to reuse the lower mounting screws and secured the top with some bolts, washers, and locking nuts

The front of the shield was lightly painted with white paint to give the projector a white "demon eye." I am a huge fan of this when it is well executed. At certain angles, the ambient light entering through the lens will reflect off the white paint and make the projector lens appear white. The Lexus projector has a nice flat surface over the shield solenoid which makes it a fairly effective projector for this mod. Also, the Tesla headlight allows a decent amount of light into the projector as it isn't located very far back in the housing, it is towards the front without a lot of overhang so this seemed like a great build for a demon eye. This paint does not affect output at all.

Peekaboo

High-beam connections were soldered together

Time for some aesthetics

I was expecting the DRL diffuser to pop out from the chrome/silver trim, but it didn't they are actually the same piece of plastic

...so I had to bust out the tape

Detail

After Paint

Tape removed

The turn signal diffuser or "shelf" was originally clear on the bottom and front, while the top was chrome, after stripping the complete unit was transparent.

...until I painted it

Reassembled

I think I reached my limit for posting pictures so I will continue in the next post.

- - - Updated - - -

I have a bunch more photos but the site says I exceeded my picture quota, not sure what I have to do to raise it or have it lifted but I assume it is because I am newcomer to TMC.
Hopefully I can get it resolved soon so I can share more pics and info with you guys!

Evan
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Well done, I like it. Not just aesthetic but also technical improvement.

What years of the Lexus RX350 are good? Where did you get the projectors, at the junkyard? How did you get the clear plastic off the Tesla headlight?

I'm not clear where you say "High-beam connections were soldered together". What exactly? Did you end up using the large Tesla board?
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Great work! But what exactly am I looking at in the 3rd and 4th photo?

Thanks for sharing. Looking forward to more pics.
�

Excellent! More photos...
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Edmond said: ?

Well done, I like it. Not just aesthetic but also technical improvement.

What years of the Lexus RX350 are good? Where did you get the projectors, at the junkyard? How did you get the clear plastic off the Tesla headlight?

I'm not clear where you say "High-beam connections were soldered together". What exactly? Did you end up using the large Tesla board?
Click to expand...

Exactly what I aim for: increasing function and form. Any Lexus RX350 projector is good technically the RX350 started in 2007 at the tail end of the 2nd Gen (03-08) but that 07/08 RX350 projector is a low-beam only model and is identical to the one found in the more common RX330 from 2003-2007. The projector I used was from the 3rd Gen RX350 which was made 2008-2012 and was a Bi-xenon unit. So to recap any Rx330/350 projector is a solid performer, especially after some modding but if you want the bi-xenon unit it will have to be from a 2008+ RX350. I source my projectors from all over, Craiglist, eBay, HIDPlanet.com (forum), and TheRetrofitSource.com, I believe these particular units were from eBay.

The plastic lens was removed after I put the headlight in the oven to warm the perma-seal, I then used some tools to scour, pull, and pry the lense off. It takes some time and technique but wasn't too bad compared to some other headlights.

For the high beam, the Tesla had some wires running from the board to the projector, I simply cut them and soldered in the proper connection for the RX350 solenoid (black connector w/ white/brown wires in the photo). The board was left in place unmodified.

Yonki said: ?

Great work! But what exactly am I looking at in the 3rd and 4th photo?

Thanks for sharing. Looking forward to more pics.
Click to expand...

Good question, I forgot to add notes to those photos and this forum doesn't allow me to edit my post (at least at this moment).

Between the 2 output shots, notice a couple things:

- Sharpness/clarity: The Tesla projector with it's fresnel lens diffuses some light and make the cutoff soft and unfocused, where the RX350 is very sharp due to the clear lens. Clear lenses do not increase the amount of light but rather increase the control and direction of it, more light goes where you need it and less where you don't (diffused).

- Light distribution: The Tesla has a majority of it's light output centered directly underneath the cutoff, this is called the hotspot and the greater the intensity and size of the hotspot the further you will be able to see in that area, in this case, directly in front of you down the road. The hotspot is only part of the story.

- Foreground: Foreground is the light near the bottom of the beam patterns and illuminates the road near the front of the car, much like many fog lights, this helpful for city/urban driving while at slower speeds; however having too much foreground will impede distance vision, think of driving at night with a Nav screen on full brightness vs. no interior lights on at all, same things applies to car headlights, both the Tesla and Lexus have adequate yet not overly strong foreground.

- Cutoff/Width: The cutoff on the Tesla bowes downward and thins out the wider the beam gets, effectively reducing the range of your beam width. In general, the most useful light from a projector is the light along the cutoff, this is an area that the Lexus really shines. If you look at the picture of the RX350 you can see there are some fingers/striations of light that run just under the cutoff and reach outward, very FUNCTIONAL light. The Tesla essentially has none where the RX350 has those strong fingers of light.

Light Quality: Not nearly as important of the other variables but worth noting, the Tesla has more layered/feathered light distribution (these are not technical terms, just jargon from my brain), in contrast the Lexus, in general, has a very smooth light output. The beam pattern (smooth, chunky, streaky, blotchy, etc) has to be REALLY bad to negatively impact function and the quality of the light is more about aesthetics since it is pleasant for the operator of the vehicle to look at and is usually found on high quality projectors with high quality reflective bowls: size, shape, and fit/finish.

Hope this helps,
Evan
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Since you're in the OC... how much?? :love:
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Coming from the fully adaptive LED headlights in my BMW and adaptive lights in 535, the lights in the Model S for lack of a better term: suck. I can deal with the fact that they're not adaptive but the light output is poorly thought out. The beams appear to cross and there is a ton of glare as your "before" picture show.

I'm relatively confident Tesla is going to roll out a facelifted S that will have the Model X LED headlights and much like the BMWs, we'll figure out how to retrofit them on the older cars assuming they physically fit the same opening. I'm holding out hope for that.

I wouldn't mind paining the inside of the housing black in the interim though. On a white car that would look wicked.
�

I found your post on Instagram and love it!

Too bad I'm million miles away and can't ask for your ingenious help on this upgrade
�

That's pretty cool. I think I would be happy with just the aesthetic upgrade. That looks like a cheap mod.
�

?HERE ARE THE REMAINING PICTURES

Direct sunlight

Detail

Demon eye in full effect

Comparison

MORE OUTPUT SHOTS

Tesla Low: oem ballast oem bulb

Tesla High

RX350 Low: 35w denso slim, xb35 5k

RX350: Camera on Auto

Tuned with 1mm washers between lens holder and bowl, STI-R was already sitting flush/forward in the holder.

Peace

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Well there's just not enough detail here to actually do this.
�

Can we see some picture of the front end of the car with the new setup?
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Edmond said: ?

Well done, I like it. Not just aesthetic but also technical improvement.

What years of the Lexus RX350 are good? Where did you get the projectors, at the junkyard? How did you get the clear plastic off the Tesla headlight?

I'm not clear where you say "High-beam connections were soldered together". What exactly? Did you end up using the large Tesla board?
Click to expand...

Absolutely, both are always the goal but if there is conflict then function wins.
eBay, Craiglist, HIDPlanet.com (forum), and TheRetrofitSource.com are the places I track down most my retrofit stuff.
During the Gen 2 of the Lexus RX there was a low-beam only RX-350 in 07/08, it is exactly the same as the RX330 projector found from 03-07, the one I am using is from the Gen 3 RX350 made from 08-13 IIRC and it is bi-xenon. All are excellent performers.
There are 2 wires that run to the projector, they connect to the solenoid which activates the low/high shield. The RX projector used a different connection so I have so mate the wires together. Board is left in place untouched.

Yonki said: ?

Great work! But what exactly am I looking at in the 3rd and 4th photo?

Thanks for sharing. Looking forward to more pics.
Click to expand...

Man, I wrote you a very long and thorough explanation to this last night and when it posted it I received a message saying it had to be reviewed by the moderators before it could be posted. It has still not surfaced yet my typing and picture posting privileges seem to be reinstated. I will try to recap:
*it will be helpful to open the photos in a different window to reference when while reading through these explanations*

- Sharpness and clarity: The Tesla has a fresnel lens which diffuses a little bit of light, you can see this by how soft and fuzzy the cutoff is relative to the sharpcutoff on the RX

- Hotspot: The concentration of light in the middle of the beam pattern. Both have decent hotspots, the Tesla's is slightly larger. This "hot-spot" of light is great for distance vision and and high speed driving.

- Cutoff: In addition to the sharpness, notice how flat the RX cutoff is, the Tesla bows downward.

- Light Along Cutoff: In addition to the downward bowing the Tesla also has very poor output on the outer edges of the cutoff, this is the area where the Lexus really shines as it has these fingers or striations of light which reach outward. Light intensity along the cutoff is VERY useful light. If you are driving at >20mph then you will really only be using the upper portion of the beam pattern, so if you reference the photos and look at the areas of high intensity light, the Tesla is only in the middle so you can only see (well) directly in front of you. The Tesla is like a zoom lens on a camera where the Lexus is like a wide-angle.

- Light Quality: This is not nearly important as the other variables discussed but worth noting. Depending on the design of the projector the light output can have different appearances/distributions: streaky, blotchy, smooth, etc. These are not the best examples to compare but the Lexus has a much more uniform light output and the light looks smooth. The "quality" of the light doesn't really have much of an impact of real-world performance, it is more for enjoyment as the light distribution is more pleasant to look at for most people.

Mike K said: ?

Coming from the fully adaptive LED headlights in my BMW and adaptive lights in 535, the lights in the Model S for lack of a better term: suck. I can deal with the fact that they're not adaptive but the light output is poorly thought out. The beams appear to cross and there is a ton of glare as your "before" picture show.

I'm relatively confident Tesla is going to roll out a facelifted S that will have the Model X LED headlights and much like the BMWs, we'll figure out how to retrofit them on the older cars assuming they physically fit the same opening. I'm holding out hope for that.

I wouldn't mind paining the inside of the housing black in the interim though. On a white car that would look wicked.
Click to expand...

I have seen some shots of Model S LED development headlight so it definitely is in the works, rightfully so. Other than specs and seeing them during the day, I have no experience with the "real world" performance of the Model X headlights, I am a huge fan of how they look though.

Many of the modern LED headlamps can't raise a candle to a proper HID setup. They will, and they will continue to increase in performance way beyond what an HID setup could do, but they are not there yet. The multi optic/cluster/matrix headlamps are great for precisely placing light but in terms of light intensity, the HID is still king. All of us headlight enthusiasts squeal with excitement during the release of a new LED headlamp and then once we get our hands on them and test them, are left unimpressed. One of the most impressive offerings on the market is the new Acura RLX headlamps, it surpasses anything from BMW, Mercedes, Jag, Nissan, VW/Porsche, Toyota/Lexus, and even the older Acuras like the MDX, but it is still a 2nd to a nice projector.

ifung90 said: ?

I found your post on Instagram and love it!

Too bad I'm million miles away and can't ask for your ingenious help on this upgrade
Click to expand...

Are you LHD or RHD? Why wouldn't it be possible?

stevem said: ?

That's pretty cool. I think I would be happy with just the aesthetic upgrade. That looks like a cheap mod.
Click to expand...

You need to go for a ride in a car with legitimate headlights! I guarantee you will change your mind.

Evan
�

Sorry for the delay, I guess something with my account was triggering the SPAM filters on the site and everything I was trying to post went to "review" with the moderators and would never appear in the thread, so I was without a voice for a bit but I think the issue has been resolved, so let's continue.

Mike K said: ?

Coming from the fully adaptive LED headlights in my BMW and adaptive lights in 535, the lights in the Model S for lack of a better term: suck. I can deal with the fact that they're not adaptive but the light output is poorly thought out. The beams appear to cross and there is a ton of glare as your "before" picture show.

I'm relatively confident Tesla is going to roll out a facelifted S that will have the Model X LED headlights and much like the BMWs, we'll figure out how to retrofit them on the older cars assuming they physically fit the same opening. I'm holding out hope for that.

I wouldn't mind paining the inside of the housing black in the interim though. On a white car that would look wicked.
Click to expand...

I have seen some shots of Model S LED development headlight so it definitely is in the works, rightfully so. Other than specs and seeing them during the day, I have no experience with the "real world" performance of the Model X headlights, I am a huge fan of how they look though.

Many of the modern LED headlamps can't raise a candle to a proper HID setup. They will, and they will continue to increase in performance way beyond what an HID setup could do, but they are not there yet. The multi optic/cluster/matrix headlamps are great for precisely placing light but in terms of light intensity, the HID is still king. All of us headlight enthusiasts squeal with excitement during the release of a new LED headlamp and then once we get our hands on them and test them, are left unimpressed. One of the most impressive offerings on the market is the new Acura RLX headlamps, it surpasses anything from BMW, Mercedes, Jag, Nissan, VW/Porsche, Toyota/Lexus, and even the older Acuras like the MDX, but it is still a 2nd to a nice projector.

ifung90 said: ?

I found your post on Instagram and love it!

Too bad I'm million miles away and can't ask for your ingenious help on this upgrade
Click to expand...

Are you LHD or RHD? Why wouldn't it be possible?

stevem said: ?

That's pretty cool. I think I would be happy with just the aesthetic upgrade. That looks like a cheap mod.
Click to expand...

You need to go for a ride in a car with legitimate headlights! I guarantee you will change your mind.

Edmond said: ?

Well there's just not enough detail here to actually do this.
Click to expand...

I don't follow...

!S4 said: ?

Can we see some picture of the front end of the car with the new setup?
Click to expand...

I will post pictures once these go on a car, these particular ones don't have a home yet but I would like for them to get on an Orange County Car so I can do the install and test them and also try a few different things for future builds.

Evan
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Outstanding work Evan! Excellent post.
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SPXMike said: ?

Outstanding work Evan! Excellent post.
Click to expand...

Thank you very much!

I will update this thread with the actual output shots of these headlights but since the beam pattern pictures I posted earlier are not the best representation of REAL WORLD performance, below are some output shots of my personal vehicle, a BMW E61 wagon, and my girlfriend's Gen II Prius. These pictures more accurately portray what can be expected from a properly tuned, high-quality projector.

My E61 runs a Morimoto MH1 7.0 projector (Bi-Xenon) and the Prius has modded/tuned Acura RL projectors (low beam only), both are running 50w ballasts.

Feel free to ask any questions!
Evan

My E61

Gen II Prius

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Ever been to Colorado? Want to come to Colorado? I'd love to be the test car.

ucsbwsr said: ?

Sorry for the delay, I guess something with my account was triggering the SPAM filters on the site and everything I was trying to post went to "review" with the moderators and would never appear in the thread, so I was without a voice for a bit but I think the issue has been resolved, so let's continue.

I have seen some shots of Model S LED development headlight so it definitely is in the works, rightfully so. Other than specs and seeing them during the day, I have no experience with the "real world" performance of the Model X headlights, I am a huge fan of how they look though.

Many of the modern LED headlamps can't raise a candle to a proper HID setup. They will, and they will continue to increase in performance way beyond what an HID setup could do, but they are not there yet. The multi optic/cluster/matrix headlamps are great for precisely placing light but in terms of light intensity, the HID is still king. All of us headlight enthusiasts squeal with excitement during the release of a new LED headlamp and then once we get our hands on them and test them, are left unimpressed. One of the most impressive offerings on the market is the new Acura RLX headlamps, it surpasses anything from BMW, Mercedes, Jag, Nissan, VW/Porsche, Toyota/Lexus, and even the older Acuras like the MDX, but it is still a 2nd to a nice projector.

Are you LHD or RHD? Why wouldn't it be possible?

You need to go for a ride in a car with legitimate headlights! I guarantee you will change your mind.

I don't follow...

I will post pictures once these go on a car, these particular ones don't have a home yet but I would like for them to get on an Orange County Car so I can do the install and test them and also try a few different things for future builds.

Evan
Click to expand...

�

Edmond said: ?

Well there's just not enough detail here to actually do this.
Click to expand...

ucsbwsr said: ?

I don't follow...
Evan
Click to expand...

Hi Evan, very nice mod, your work is quite impressive (i can only judge aesthetics, and presume the technical results).
What Edmond I think he meant is you didn't wrote in depth details of how someone else can replicate this (maybe in the future you'll have time to write a HID improvements for dummies, eg what exact part did you paint white, where to get the D1S to D2S adapter and so on).

At least i know how to do the first step, to bake a headlight :biggrin:

- - - Updated - - -

LE: The red circled thing is the shield, the part responsible for high/low beam and the one you painted white?

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Wow. Typically I'm not a fan of aftermarket aesthetic changes, as it typically goes too far and looks a little too "much" for my tastes, but wow that is some really sweet looking headlights.

I've love to see the finished product on the car compared to the old.

And your BMW lights look awesome!
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Sm4llz said: ?

Ever been to Colorado? Want to come to Colorado? I'd love to be the test car.
Click to expand...

I have been there, like it very much. Yes, I do want to come back, I have never spent time in Boulder and would love to check it out. (I know this was a rhetorical statement) but in all seriousness when I hear Colorado I think of trees and dark roads, and of course high-performance headlights! :-D

tomsky said: ?

Hi Evan, very nice mod, your work is quite impressive (i can only judge aesthetics, and presume the technical results).
What Edmond I think he meant is you didn't wrote in depth details of how someone else can replicate this (maybe in the future you'll have time to write a HID improvements for dummies, eg what exact part did you paint white, where to get the D1S to D2S adapter and so on).

At least i know how to do the first step, to bake a headlight

- - - Updated - - -

LE: The red circled thing is the shield, the part responsible for high/low beam and the one you painted white?
Click to expand...

Thanks for the kind words, there is a lot to gain in both aesthetics and function from a well executed headlight build. These Tesla headlights now look pretty "tough" but the best part is they have the performance to back up their looks! ...just like my wagon, it looks aggressive but it also carries 550whp in it's back pocket.

My thread wasn't supposed to be a DIY, I tend to be so detailed in my explanations and photo documentation that it comes close but that wasn't my intent but I can probably put something together down the road if the TMC community is interested. In the meantime I can can address your question about the demon eye and shield painting as well as show some of the steps I took for tuning the projector.

Here is a picture of the Lexus projector mounted to the Tesla bracket. The Lexus projector is comprised of 4 major parts: lens, lens holder, shield/solenoid, and the reflective bowl which houses the HID bulb. The complete projector is mounted to the black bracket with some bolts, washers, and locking nuts.

To achieve the "demon eye" effect, I disassembled the projector and lightly applied paint to the front side of the shield, it is important to apply paint lightly as heavy coats can impede the activation of the shield when using high-beams. It wasn't as important with this RX350 projector since the shield pivots on a transversely mounted rod and actually tilts backwards (towards the bulb) when activated, most of the pivot points are projected from paint. Some projector shields tilt-forward and have their springs and other components exposed, others shield designs slide downward with a scissoring motion, paint can really screw these designs up if not applied correctly and the shield can get stuck, blinding oncoming traffic, no bueno. The box you highlighted is actually a cover for the high-beam solenoid and is one of the reasons I decided to implement a demon eye on this projector, is is a nice smooth surface which will offer a uniform white appearance from many external angles while viewing the Tesla headlights.

Here is an up close and personal shot. The cutoff shield is underlined in red, notice that there is no paint on the top. The optics of the projector are very sensitive and even a small dusting of paint can have a negative impact on the output. Light output and intensity are not affected, rather gobs of paint (or even a rough shield surface) can give you a grainy/rough looking cutoff so it is more of an aesthetics issue but something I address nonetheless. Also, the blue circle highlights an area where there used to be some metal that extended up towards the top of the shield and there was juuuuuuuust enough to have an optical impact on the cutoff, with the little metal tab in place it was positioned about 1mm-2mm in front of the shield and that was enough to be out of focus. The metal tab created a little soft/fuzzy looking hump in the cutoff so it was removed. Again this a small detail but a necessary step in the tuning process to make the light output sexy! If you notice at the very top of the photo how the metal bowes downward in the middle, that is a foreground limiter and the more aggressive that is (closer it gets to the cutoff shield, the more light will be limited directly in front of your vehicle, too much foreground can create glare for the driver and make it hard to view distant objects, especially on wet roads so most projectors have some sort of limiter like this.

Front

Rear

JMG said: ?

Wow. Typically I'm not a fan of aftermarket aesthetic changes, as it typically goes too far and looks a little too "much" for my tastes, but wow that is some really sweet looking headlights.

I've love to see the finished product on the car compared to the old.

And your BMW lights look awesome!
Click to expand...

Thank you. OEM+, clean, simple, subtle is much more my style than flashy and flamboyant, my BMW headlights are a good example of this as I deleted the factory "angel eye" DRLs all together, the design of the headlight is creased, sharp, and aggressive; and with those circular rings were distracting and took away from the overall design. The headlight is much sleeker now, similar to the Tesla unit!

I will take some comprehensive before and after photos of these headlights on a Model S both how they look on the car and how the real-world performance compares to stock, lol stock...

Cheers,
Evan
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I think this would look amazing on my black MS!! I love it and the improved optics is a nice bonus! Great job.
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Your BMW E61 wagon looks amazing. I wish I had black wheels on my white MS. Your lamps would be the finishing touch.
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Amazing the difference a little spray paint can make in looks. Anxious to see it on a car. I suspect with all the jerry-rigging the alignment may be a challenge.
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3s-a-charm said: ?

I think this would look amazing on my black MS!! I love it and the improved optics is a nice bonus! Great job.
Click to expand...

Black headlights inherently offer a sportier look and would be a visual upgrade on any color. On a Model S with blacked out trim or dark wheels it would really complete the look. Of course on a black car it would be straight murder!

Camera-Cruiser said: ?

Your BMW E61 wagon looks amazing. I wish I had black wheels on my white MS. Your lamps would be the finishing touch.
Click to expand...

Thank you, it is a lot of fun. It is hard not to like the good ol' Storm Trooper color combo!

jcaspar said: ?

Amazing the difference a little spray paint can make in looks. Anxious to see it on a car. I suspect with all the jerry-rigging the alignment may be a challenge.
Click to expand...

Chrome and amber are some of my sworn headlight enemies, I can't stand them.

Maybe I should wait and respond to this after I get the alignment dialed but I think it should be fairly straightforward. When mounting the projector to the brackets I made most of the holes oval shaped so I had a little bit of room for rotational adjustment.

Evan
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Absolutely fantastic work, and great details of the process! I'm down in San Diego but if you want a test car I may offer myself up. Been wanting to do some similar improvements to my headlights but haven't gotten around to it.
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Wow, just wow. Nice work.
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Jool said: ?

Absolutely fantastic work, and great details of the process! I'm down in San Diego but if you want a test car I may offer myself up. Been wanting to do some similar improvements to my headlights but haven't gotten around to it.
Click to expand...

Thanks for the kind words and thanks for offering your Tesla. I will be looking for one locally here in Orange County but I will let you know if I am having trouble tracking someone down.

supratachophobia said: ?

Wow, just wow. Nice work.
Click to expand...

Thank you.
�

This is fantastic... If you ever start selling these retrofits, I'll be one of the first in line to buy one!
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- The D1S-D2S ignitors arrived and after some small modification plugged right in. The fitment and orientation of the components inside the housing is perfect, not much extra room but enough to easily access the bulb if needed and don't interfere with the housing cap.

- The second group of pictures are more output shots, this time I ran the oem Tesla projector with the same Morimoto bulb and 50w ballast as the Lexus RX350 projector so can you how A) the Tesla looks at 55W and B) how the projectors stack up in an apples-to-apples comparison.

Evan

OUTPUT SHOTS: Same bulb and ballast for both projectors

Tesla @10ft, exposure lowered.

Lexus @10ft, exposure lowered

Tesla @18ft

Lexus @18ft

Tesla @18ft, exposure lowered

Lexus @18ft, exposure lowered

Tesla @18ft, detail

Lexus @18ft, detail

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Just for reference (and fun), here are some pictures of the output from the projectors from a Lexus SC430 (2001-2010 Convertible).

In my opinion, the best performing projector on the market. It has excellent width, intensity, and light distribution. Unfortunately this is a low-beam only projector so it is not the best fit for all headlights as it does not offer any high-beam functionality. For example, you would have to forego high-beam function if you ran these on the Model S. But my goodness, it's performance is flawless.

These particular projectors I tuned with clear lenses from a BMW E30 and lens spacing to achieve and sharp and colorful cutoff.

Please enjoy,
Evan

So sharp

Compared to the Model S

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Sounds like a lot of people are interested in seeing these on a Model S. I had my headlight housing painted black exactly as shown I believe. I haven't taken any great pics, but I'll post the few I have saved on my phone.

I definitely like them way better than the stock. Also a side note - my fog lights are tinted because the clear/white fog lights did not match the black nose cone and headlights. I really feel like these headlights match the nosecone and styling of the car perfectly. I am also getting new wheels soon that better match the dark color theme with lighter accents

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ThatGoogleGuy said: ?

Sounds like a lot of people are interested in seeing these on a Model S. I had my headlight housing painted black exactly as shown I believe. I haven't taken any great pics, but I'll post the few I have saved on my phone.

I definitely like them way better than the stock. Also a side note - my fog lights are tinted because the clear/white fog lights did not match the black nose cone and headlights. I really feel like these headlights match the nosecone and styling of the car.
Click to expand...

Your pictures are not working. I'd love to see them!
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Ingineer said: ?

Your pictures are not working. I'd love to see them!
Click to expand...

Sorry! It's fixed now
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ThatGoogleGuy said: ?

Sorry! It's fixed now
Click to expand...

Those look great, I love the darker look without any reduction in light output (as can happen with tinting).
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ThatGoogleGuy said: ?

Sounds like a lot of people are interested in seeing these on a Model S. I had my headlight housing painted black exactly as shown I believe. I haven't taken any great pics, but I'll post the few I have saved on my phone.

I definitely like them way better than the stock. Also a side note - my fog lights are tinted because the clear/white fog lights did not match the black nose cone and headlights. I really feel like these headlights match the nosecone and styling of the car perfectly. I am also getting new wheels soon that better match the dark color theme with lighter accents
Click to expand...

Those look brilliant! Definitely going to do something similar to my headlights since I already have dark wheels and plan to black out most of the chrome trim Thanks for the photos!
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ThatGoogleGuy said: ?

Sorry! It's fixed now
Click to expand...

Thanks for sharing your pictures.

So you tinted your fogs to darken the chrome of the cornering light? Chrome bowls can really be distracting of dark/blacked out cars and it puts one in a predicament of aesthetics vs function. Unfortunately with the way the corner light is designed on the Tesla there is no compromise, one or the other. I assume you tinted the entire lens but you may be able to cut out a window for the projector fog to shine through since that is at the small lens at the bottom, you could gain 100% fog functionality with little to no visual impact on the look you are going for, something to consider if you miss the fog output.

Evan
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Can you please just shut-up and start taking our money?
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ucsbwsr said: ?

Thanks for sharing your pictures.

So you tinted your fogs to darken the chrome of the cornering light? Chrome bowls can really be distracting of dark/blacked out cars and it puts one in a predicament of aesthetics vs function. Unfortunately with the way the corner light is designed on the Tesla there is no compromise, one or the other. I assume you tinted the entire lens but you may be able to cut out a window for the projector fog to shine through since that is at the small lens at the bottom, you could gain 100% fog functionality with little to no visual impact on the look you are going for, something to consider if you miss the fog output.

Evan
Click to expand...

Thanks for the advice, that definitely sounds like a smart idea. You are on point, when I turn on my fogs I actually don't see anything happen anymore, so that would really help.
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I've been in touch with Evan. He lives relatively close to me. We'll get these lights on my car and get pics posted when we have a chance. My car is Obsidian Black Metallic with 21" grey turbines so the Demon Eyes should look pretty good. Also I've asked Evan to PM a member more knowledgeable about the electrical aspects of the car. Switching headlight projectors seems innocent enough, but you never know. I think Evan has a pretty good thing going, but there are the legal aspects (void my warranty?) and production aspects (access to replacement headlights by someone other than an approved body shop) that need to be worked out. We'll keep you posted.
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SPXMike said: ?

I've been in touch with Evan. He lives relatively close to me. We'll get these lights on my car and get pics posted when we have a chance. My car is Obsidian Black Metallic with 21" grey turbines so the Demon Eyes should look pretty good. Also I've asked Evan to PM a member more knowledgeable about the electrical aspects of the car. Switching headlight projectors seems innocent enough, but you never know. I think Evan has a pretty good thing going, but there are the legal aspects (void my warranty?) and production aspects (access to replacement headlights by someone other than an approved body shop) that need to be worked out. We'll keep you posted.
Click to expand...

Thanks for the response on this. In all seriousness, he may have very well created a great after-market product for Tesla owners. I would not say that I'm entirely disappointed with the factory lighting, but as I get older, quality precision lighting at night becomes of a greater and greater value to me, I have found. And to see the aesthetics improved as well is just an added bonus.

Headlights are a very serious part of safely operating the vehicle, so please let us know what you find. It really seems like he knows what he is doing, I mean, the guy even wears fancy gloves in the pictures. You can't wear fancy gloves for a project and not be a professional right?
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Just in case people are wondering I did an experiment to see if the Body ECU is ok with higher loads on the headlight circuit. I applied a 5.5A load (> 65w) and it ran overnight no problem, and the body ECU doesn't have any components getting too hot.

Now this green lights projector upgrades beyond the 35w stock.

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In anticipation of ucsbwsr making this happen I purchased salvage right and left headlamps today on eBay. They are "insurance" grade with no damage. Got them for $600. I want to be the first to ship ucsbwsr a set for modification

My wife's Honda CRV lights up the road much better than my Model S. I've been disappointed with the performance of the headlamps from day 1. They are not worthy of the car's handling and capabilities . I also had a Honda S2000 a while back, which set a standard for headlight performance that my Model S fails big time.
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artsci said: ?

In anticipation of ucsbwsr making this happen I purchased salvage right and left headlamps today on eBay. They are "insurance" grade with no damage. Got them for $600. I want to be the first to ship ucsbwsr a set for modification

My wife's Honda CRV lights up the road much better than my Model S. I've been disappointed with the performance of the headlamps from day 1. They are not worthy of the car's handling and capabilities . I also had a Honda S2000 a while back, which set a standard for headlight performance that my Model S fails big time.
Click to expand...

You should try the Aussie Model S lights then. Tesla had to downgrade the power rating of the lights otherwise local design rules would have required headlight washers
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supratachophobia said: ?

Thanks for the response on this. In all seriousness, he may have very well created a great after-market product for Tesla owners. I would not say that I'm entirely disappointed with the factory lighting, but as I get older, quality precision lighting at night becomes of a greater and greater value to me, I have found. And to see the aesthetics improved as well is just an added bonus.

Headlights are a very serious part of safely operating the vehicle, so please let us know what you find. It really seems like he knows what he is doing, I mean, the guy even wears fancy gloves in the pictures. You can't wear fancy gloves for a project and not be a professional right?
Click to expand...

An extra set of mountain bike gloves definitely have their place in headlight retrofitting world! I like what you said about properly functioning headlights and safety. A proper projector setup not only makes it safe for the driver as he can see the road better, it also makes it safer for oncoming traffic with precise light control (assuming the headlights are aimed properly).

doctorwho said: ?

You should try the Aussie Model S lights then. Tesla had to downgrade the power rating of the lights otherwise local design rules would have required headlight washers
Click to expand...

I was contacted by a Norwegian member who suffers from the same fate, 25w factory ballasts.

artsci said: ?

In anticipation of ucsbwsr making this happen I purchased salvage right and left headlamps today on eBay. They are "insurance" grade with no damage. Got them for $600. I want to be the first to ship ucsbwsr a set for modification

My wife's Honda CRV lights up the road much better than my Model S. I've been disappointed with the performance of the headlamps from day 1. They are not worthy of the car's handling and capabilities . I also had a Honda S2000 a while back, which set a standard for headlight performance that my Model S fails big time.
Click to expand...

The Model S are far from the worst headlights on the road but considering how good they could be there is a large separation in performance; I also think people expect higher performance when considering the price of the Model S and the other technologies packed into the car.

S2000s are serious projectors with great intensity and width, unfortunately they are a low-beam only units so there application is limited.

Evan
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There'd be a potentially big Aussie market for a decent after-market light mod kit
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doctorwho said: ?

There'd be a potentially big Aussie market for a decent after-market light mod kit
Click to expand...

Might be an even bigger market in Norway with close to 10.000 Model S sold since 2013. 25W balasts is like stepping a couple of decades back in time.

It's pretty dark here 6-8 months out of a year as well

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I'm in for a 55W HID retrofit. What is the recommended ballast and bulb?
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I am still working to get everything in order on my end before I start to accept builds/orders, so if you are eager, please sit tight and if you are curious about this modification I will continue to add info and pictures which should be helpful.

In the near future I will try to take some better output shots of the oem projector vs the Lexus, as well as 35w Tesla ballast vs 35w Denso (Lexus) ballast vs aftermarket 50w Morimoto ballast to show the differences in warm up time and light output.

In the meantime here are some interesting pics of a naked (chrome stripped) Model S housing, too bad the shroud and the plastic below are not transparent, there could have been a throwback "clear phone" option for the headlight build. If you funky like that....

Evan

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FlatSix911 said: ?

I'm in for a 55W HID retrofit. What is the recommended ballast and bulb?
Click to expand...

I will cover bulb options later with output pictures and description of each bulbs. In general I recommend bulbs from Osram, Philips, and Morimoto. In general oem options like Philips and Osram tend to have a more polished product with excellent performance. Morimoto which in my opinion is the premier aftermarket brand is a very compelling option as real-world performance is very similar and when you factor the lower cost and included warranty it strengthens the appeal. There are a few key areas which separate high performance bulbs from the average. One is the alignment, if the glass capsule of the bulb isn't built and aligned properly with the base it can cause some misalignment and severely impede performance making the output dim with spotty light distribution, the optics in HID projectors are very sensitive. The other is the quality of the salts used in the bulb. There are some other build-quality related issues that come into play but those apply to lesser bulbs, not really applicable to the options above.

One thing to keep in mind for those interested in running an uprated 50/55w ballast is there will be a color-shift from the added power. I will go into this in greater detail later but in a nutshell, a bulbs Kelvin Rating (K) is the color temperature of the light it puts out:

3,000k - Very yellow
4,000-4,600k - White w/ a hint of yellow
5,000-5,500k - Pure white
6,000k - White with blue tinge
6,500k - Blueish white
7,000k - No, Stop, Don't!

Optimum light output occurs around 4,300k and that is what oem manufacturers use, as you move up the kelvin scale to 5k and then 6k there is a slight decrease in raw output but many people opt for these higher kelvin ratings as aesthetically the light is more pleasing and worth the slight hit in lumens. For example, the DRL on the Model S looks to be pretty pure white (~5,000-5,300k) and purely from an aesthetics standpoint I would try to match the output of the bulb to the DRL, of course 4,300k bulbs would offer ideal output but may look a little yellow compared to the DRL. What's the worst is people who have headlights with large halogen reflective bowls (think Toyota Tacoma or Ford F-250) and swap the halogen bulb for a 6k or 8k HID kit, not only are the halogen bowl optics not meant to work with an HID bulb, so light is thrown everywhere with no precision, the blueish color not only offers decreased output for the driver (relative to 4,300k) but the blueish light output is harder on the human and adds stress for the driver and more glare for oncoming traffic. Just dangerous all around.

The kelvin rating on bulbs is based off a 35w input and when the power is increased to 50/55w there is a color shift of ~1,000k down the scale, meaning a 6k bulb @35w is 6k output, while a 6k bulb @50w is 5k output and this must be considered when piecing together a headlight build.

Also, it is important to note that when "boosting" a bulb with an uprated 50/55w ballast there will be a slight decrease in the bulbs life expectancy, about -18% shorter life, the trade off is the increase in light output +18%. Additionally, the increased bulb output can also make a projector bowl age sooner than it would at lower wattage. The chrome coating on the inside of the bowl can become hazy or blistered from bulb heat and UV exposure and make light output suffer. UV is the main culprit in damaging reflective bowls and the amount of UV emitted can very from bulb to bulb but in general higher quality bulbs will have better controlled and lower lower levels of UV light emitted. There has been some data showing that bulbs with a higher kelvin rating also emit more UV light. Again things to think about if you are interested in a higher wattage ballast. If you don't mind some added wear and tear on the components and want the added output then an upgraded ballast may be for you, if you are looking for the absolute more reliable light setup then I would recommend sticking to a high quality 35w ballast.

More to come,
Evan
�

Evan, great information in your post.
I am looking forward to upgrading my OEM HID 35W bulbs to a 55W retrofit in the 5,000-6,000k range - Pure white to match the LED DRL.

ucsbwsr said: ?

I will cover bulb options later with output pictures and description of each bulbs. In general I recommend bulbs from Osram, Philips, and Morimoto. In general oem options like Philips and Osram tend to have a more polished product with excellent performance. Morimoto which in my opinion is the premier aftermarket brand is a very compelling option as real-world performance is very similar and when you factor the lower cost and included warranty it strengthens the appeal. There are a few key areas which separate high performance bulbs from the average. One is the alignment, if the glass capsule of the bulb isn't built and aligned properly with the base it can cause some misalignment and severely impede performance making the output dim with spotty light distribution, the optics in HID projectors are very sensitive. The other is the quality of the salts used in the bulb. There are some other build-quality related issues that come into play but those apply to lesser bulbs, not really applicable to the options above.

One thing to keep in mind for those interested in running an uprated 50/55w ballast is there will be a color-shift from the added power. I will go into this in greater detail later but in a nutshell, a bulbs Kelvin Rating (K) is the color temperature of the light it puts out:

3,000k - Very yellow
4,000-4,600k - White w/ a hint of yellow
5,000-5,500k - Pure white
6,000k - White with blue tinge
6,500k - Blueish white
7,000k - No, Stop, Don't!

Optimum light output occurs around 4,300k and that is what oem manufacturers use, as you move up the kelvin scale to 5k and then 6k there is a slight decrease in raw output but many people opt for these higher kelvin ratings as aesthetically the light is more pleasing and worth the slight hit in lumens. For example, the DRL on the Model S looks to be pretty pure white (~5,000-5,300k) and purely from an aesthetics standpoint I would try to match the output of the bulb to the DRL, of course 4,300k bulbs would offer ideal output but may look a little yellow compared to the DRL. What's the worst is people who have headlights with large halogen reflective bowls (think Toyota Tacoma or Ford F-250) and swap the halogen bulb for a 6k or 8k HID kit, not only are the halogen bowl optics not meant to work with an HID bulb, so light is thrown everywhere with no precision, the blueish color not only offers decreased output for the driver (relative to 4,300k) but the blueish light output is harder on the human and adds stress for the driver and more glare for oncoming traffic. Just dangerous all around.

The kelvin rating on bulbs is based off a 35w input and when the power is increased to 50/55w there is a color shift of ~1,000k down the scale, meaning a 6k bulb @35w is 6k output, while a 6k bulb @50w is 5k output and this must be considered when piecing together a headlight build.

Also, it is important to note that when "boosting" a bulb with an uprated 50/55w ballast there will be a slight decrease in the bulbs life expectancy, about -18% shorter life, the trade off is the increase in light output +18%. Additionally, the increased bulb output can also make a projector bowl age sooner than it would at lower wattage. The chrome coating on the inside of the bowl can become hazy or blistered from bulb heat and UV exposure and make light output suffer. UV is the main culprit in damaging reflective bowls and the amount of UV emitted can very from bulb to bulb but in general higher quality bulbs will have better controlled and lower lower levels of UV light emitted. There has been some data showing that bulbs with a higher kelvin rating also emit more UV light. Again things to think about if you are interested in a higher wattage ballast. If you don't mind some added wear and tear on the components and want the added output then an upgraded ballast may be for you, if you are looking for the absolute more reliable light setup then I would recommend sticking to a high quality 35w ballast.

More to come,
Evan
Click to expand...

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FlatSix911 said: ?

Evan, great information in your post.
I am looking forward to upgrading my OEM HID 35W bulbs to a 55W retrofit in the 5,000-6,000k range - Pure white to match the LED DRL.
Click to expand...

Sign me up as well!
�

For those of you thinking you want to make this mod, a new pair of headlights from Tesla prices out at about $1,700. I got a spare pair on eBay for about $600 but be very careful -- most of the sets or individual units sold on eBay are damaged in some way -- broken tabs, scratched lenses, etc. The best source I found was sfvautoparts. They had several undamaged units and and are upfront about any flaws.

Of course, Evan may eventually do a core exchange which will make this much easier. I'm going to opt for the 55w ballast with 6500K Morimoto bulbs. I'll have the headlamps in a day or two, ready for Evan to do his magic. I'm hoping Evan can complete my conversion so there's time to install them before the Tesla Road Trio in Williamsburg in mid May. That way I can demo them for anyone who wants to see the difference they make on the road at night.
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Nice work. I greatly appreciate the attention to detail!

One question about the turn signal lighting though:
Part of what makes the turn signal visible is that the whole turn signal piece is translucent and bounces the amber light around in the headlight housing. This makes it appear that almost the entire inside of the housing is the turn signal, and I've found it to be very visible. When viewed from in front with the turn signal illuminated, amber light lights up not only the forward edge of that element, but the entire thing, and that light also bounces off the headlight module floor and ceiling, adding to the "area" of illuminated signal. The signal is even visible from a side angle (as if you're driving along a road and a Model S is at a cross street waiting to turn left), because that lower translucent side illuminates effectively.

With your mod, it appears that by painting all of it except the forward leading edge black, and the housing interior black, you've reduced the light emitting portion of that signal to just the forward leading edge. This reduces the visible illuminating portion of the signal to a narrow, forward facing strip. This seems far less visible to me. Would you be able to show a photo comparison of your modded version with the original version illuminated?
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FlatSix911 said: ?

Evan, great information in your post.
I am looking forward to upgrading my OEM HID 35W bulbs to a 55W retrofit in the 5,000-6,000k range - Pure white to match the LED DRL.
Click to expand...

In my opinion, aiming for a 5,000-5,500k "pure white" color is a great compromise between performance and aesthetics. Although not the most efficient light temperature (as opposed to a slightly yellowish 4,300k) the white looks much better and only <5% light output is sacrificed. Of course matching HID temp to DRL temp offers a cohesive OEM+ appearance. I will do some testing on this to confirm the best color-temp matching with different bulbs at different power levels (35w vs 50w).

Cowby said: ?

Sign me up as well!
Click to expand...

Noted. When I am ready to accept orders I will try to track down everyone who has expressed interest but until then, keeping an eye on this thread will help get you educated on HID related topics and configurations that are possible in the Model S headlight.

artsci said: ?

For those of you thinking you want to make this mod, a new pair of headlights from Tesla prices out at about $1,700. I got a spare pair on eBay for about $600 but be very careful -- most of the sets or individual units sold on eBay are damaged in some way -- broken tabs, scratched lenses, etc. The best source I found was sfvautoparts. They had several undamaged units and and are upfront about any flaws.

Of course, Evan may eventually do a core exchange which will make this much easier. I'm going to opt for the 55w ballast with 6500K Morimoto bulbs. I'll have the headlamps in a day or two, ready for Evan to do his magic. I'm hoping Evan can complete my conversion so there's time to install them before the Tesla Road Trio in Williamsburg in mid May. That way I can demo them for anyone who wants to see the difference they make on the road at night.
Click to expand...

Good to know about that event, it would be great to have your lights completed so you can show others. Hopefully there is a lot of night driving and poorly light areas....

StaceyS said: ?

Nice work. I greatly appreciate the attention to detail!

One question about the turn signal lighting though:
Part of what makes the turn signal visible is that the whole turn signal piece is translucent and bounces the amber light around in the headlight housing. This makes it appear that almost the entire inside of the housing is the turn signal, and I've found it to be very visible. When viewed from in front with the turn signal illuminated, amber light lights up not only the forward edge of that element, but the entire thing, and that light also bounces off the headlight module floor and ceiling, adding to the "area" of illuminated signal. The signal is even visible from a side angle (as if you're driving along a road and a Model S is at a cross street waiting to turn left), because that lower translucent side illuminates effectively.

With your mod, it appears that by painting all of it except the forward leading edge black, and the housing interior black, you've reduced the light emitting portion of that signal to just the forward leading edge. This reduces the visible illuminating portion of the signal to a narrow, forward facing strip. This seems far less visible to me. Would you be able to show a photo comparison of your modded version with the original version illuminated?
Click to expand...

You are correct, the oem turn signal diffuser is designed to have some of the light diffused out the side. The acrylic optics directly over the turn signal LED cluster is designed to project most of the light intensity forward towards the front of the turn signal diffuser but some of that is scavenged by the "tunnel" that the light travels through to the front of the diffuser. Painting the turn signal diffuser as I did on this build will limit the amount of turn-signal light visible from the side of the vehicle.

But let's take a look at some other things...

Light intensity out the front of the diffuser shouldn't be impacted very much if at all (it would be cool to do some testing on this and see the actual results) the satin black paint which is applied to the outside of the diffuse limits the light from going through the diffuser, I am not sure if the light would be absorbed by the paint of reflected back into the diffuser, much like painting the backside of glass to make it a mirror. If the light was reflected back inside the diffuser I am not sure if the optics would usher it towards the front of the diffuser and make it useable in this application or if it would be wasted, at any rate I would love to do some testing on this when I have some time.

When looking at the design of the Model S headlight it sweeps back rather aggressively as does the turn signal diffuser, so much so that the front of the turn signal diffuser is visible from the side. Relative to the projector lens and shroud the turn signal resides at a 45-50 degree angle. If you stand at a 90 degree angle to your Model S headlight, so that your projector lens is just out of sight, you will see that about 40% of the front of the turn signal diffuser is still visible. Consequently there should be a decent amount of turn signal light visible from the side. It won't be the very intense light you would see from directly in front of the vehicle as that is where the optics throw most of the output, but there should be enough diffused light to still be easily visible. So although there won't be as much diffused/ side-visible signal light if the diffuser wasn't painted black, there will still be a decent amount. The Model S also has turn signals on the front fenders.

Leaving the "belly" of the diffuser clear like in the oem headlight would make the turn signal stand out in an otherwise black housing. For lack of a more technical description it would look like a clear-plastic hernia. lol Painting it the way I did gives the turn signal and DRL diffusers a similar width which gives the headlight a cohesive look overall. With the diffuser unpainted it would appear to be more of a block or chunk of plastic in the housing. Headlight aesthetics can be subjective so all may not agree with me but this is how it would look to me.

I will get some output shots to show how effective the signal is after being painted so people can decide for themselves but I would be surprised if the performance wasn't satisfactory for most. The owner of the vehicle will be 100% responsible for the modifications made to their headlights and how they impact safety, performance, and abide by local laws. This information is intended to be used as a reference to show the advantages and disadvantages of different modifications.

Evan

Notice the focused optics for the turn signal (orange LEDs) designed to shoot the light forward.

Turn Signal

DRL

Headlight viewed at a perpendicular angle, notice the front of the turn-signal diffuser is still visible.

�

looks good and sign me up when you are ready
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Just received the spare passenger side headlamp from sfvautoparts. It's in perfect condition -- it would be impossible to tell that it's used. Now I'm even more excited about Evan's work.

BTW, does anyone know how the headlamps are removed and reinstalled? Does the bumper have to be removed? Inquiring minds want to know
�

I still love this. I just had the chrome blacked out and think the headlamps would look awesome.

It looks like SFV had headlamps ~$350 with no broken tabs. $700 is a pretty good price if with @ucsbwsr can do the work and take existing headlamps for a core exchange price.
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Da0ne said: ?

looks good and sign me up when you are ready
Click to expand...

Noted

artsci said: ?

Just received the spare passenger side headlamp from sfvautoparts. It's in perfect condition -- it would be impossible to tell that it's used. Now I'm even more excited about Evan's work.

BTW, does anyone know how the headlamps are removed and reinstalled? Does the bumper have to be removed? Inquiring minds want to know
Click to expand...

Nice to hear about the condition of the headlight. Although having new units and perfectly clear lenses really makes the product look top notch (for both owner and retrofitter), it can be hard to justify the price difference of brand new vs lightly used, especially if one lives in an area where the weather and conditions can be hard on headlights, after all they are strapped to the front of a moving vehicle!

I have no experience with the Model S bumper or headlight install/removal procedure, I will soon. Usually it is best to remove the bumper, sometimes it is necessary for headlight removal but if nothing less it makes it easier as with the bumper you can see all mounting locations, brackets, and how they need to be aligned. It is also safer for the bumper. I will take some pictures of the process and write a small DIY for the process.

Sm4llz said: ?

I still love this. I just had the chrome blacked out and think the headlamps would look awesome.

It looks like SFV had headlamps ~$350 with no broken tabs. $700 is a pretty good price if with @ucsbwsr can do the work and take existing headlamps for a core exchange price.
Click to expand...

I would like to offer a core-exchange for those interested in executing the upgrade in an economical manner but I will have high standards for the lens condition of trade-in units so not all headlights will make the cut.
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ucsbwsr said: ?

I would like to offer a core-exchange for those interested in executing the upgrade in an economical manner but I will have high standards for the lens condition of trade-in units so not all headlights will make the cut.
Click to expand...

I've just been lurking in this thread because I find it interesting. This isn't anything I'd be interested in for myself, simply because I'm not a DIYer, and the potential issues down the road with Tesla, etc. worry me. But reading the above, I do have an idea that might help you and some people out.

You could, conceivably, have an "A" and a "B" level of core exchange, couldn't you? So units that come in that meet your very high standards are replaced with similar units. Units that don't quite meet those standard, but are pretty close get the "B" rating, and are then replaced with other "B" units.

If you started doing enough of these, you could even have a price for someone who sent in a "B" core to upgrade to an "A" unit, and a "discount" for someone who turned in an "A" unit, but who would be satisfied getting the new lights back in a "B", to keep your inventory even.

Depending on how much variation there is in these things, you could also add grades, if needed, and if the volume justified it.

Just some thoughts.

Good luck with what you are doing. It looks like you'll be providing a much needed and in-demand service!
�

Here are some more photos of:
- Modified turn signal output at different angles
- A Morimoto 6,000k bulb at 35w and 50w to show the color temperature and how it compares to the LED DRL
- Projector "demon eyes" White vs Black

Modified Turn Signal

Turn Signal on

Straight-on, the optics throw most of the light directly forward.

With a slightly wider viewing angle the intensity drops significantly

Wider angle, visible but no intense light

Perpendicular viewing angle, again no intense light but still visible.

DRL in daytime mode

DRL is low-voltage night mode

6000k bulb @ 35w & 50w ballast, color matching DRL
This is tricky to photograph as the differences are subtle and also when dropping the exposure the DRL LEDs would show flicker or at longer exposures the color temp was washed out by the intensity so I took some shots with the DRL in full-power daytime mode as well as normal night mode when they are dimmed. The color-temperature change is hard to pick up on in the photos but with this Morimoto xb35 6000k bulb both 35w and 50w match the DRL well. The 35w gives the bulb a slightly blueish appearance relative to the DRL (as expected) and when boosted with the 50w ballast color temperature looks nearly identical.

Full strength DRL, 35w ballast

Full DRL, 35w, exposure dropped

Dimmed DRL, 35w, slight drop in exposure

Dimmed DRL, 35w, exposure dropped. This is the most accurate representation of the slight color difference between the 35w ballast and DRL. Ignore the DRL flicker.

Full Strength DRL, 50w ballast, exposure dropped

DRL dimmed, 50w, normal exposure

DRL dimmed, 50w, exposure dropped

...another angle

Demon Eye Comparison
So "demon eye" is a projector modification that can be either "passive" (paint) or "active" (LEDs). A projector lens is like a magnifying glass and depending on the viewing angle, can catch and project the internal paint or LED light and make the whole lens appear that color and depending on the configuration give the car a very unique look. The effect can be very dramatic when done with LEDs as the projectors will glow with that color. One must be very careful with this modification as it is illegal to have certain colored lights emitted from the front of ones vehicle, for example blue and red are reserved for emergency vehicles like ambulances and police cars. There are no laws against passive (painted) demon eyes but it is always good to be mindful of your decision.

Where passive demon eyes will not glow like active demon eyes, at certain angles they can be very effective. I like the subtle look of a passive demon eye, it can look normal at certain angles and really pop at others. In a blacked-out headlight like this Model S, the white demon eye will offer greater contrast and give the car a little bit of character as the lens will visually "pop." The black demon eye makes the projector lens hide amongst it's black surrounding, simplifying the look of the headlight overall and giving a cleaner appearance, Think about the Model X headlights and how with their cluster LED layout, as opposed to a single projector lens, helps give the headlight a simple and uniform appearance.

If executed correctly passive demon eyes have no negative impact on light output.

LEFT: RX350 w/ white demon eye
RIGHT: Acura RL w/ black demon eye
With this photo below, notice how at this viewing angle both projector lenses are reflecting their surroundings, the Lexus shows the computer board and the Acura shows the black towel.

The design of each projector strengthens their respective demon eye color. The lens holder on the RX350 is very open and allows more ambient light in to reflect off the white paint and increase the effectiveness, normally the headlight would be assembled with the trim and lens which limits the amount of light. I contrast the Acura RL projector is mostly sealed, limiting light and making the black demon eye very dark.

The demon eyes are very noticeable when looking directly at the lens.

Another shot

For reference here is the Lexus projector before the white demon eye, on the right is the oem Tesla projector. Most projectors will have a silver appearance as without any modification the projector lens is magnifying either chrome or unfinished aluminum. Not all projectors will yield an effective demon eye, the oem Model S projector would not be a great candidate for such a modification.

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Loving all this information! When you decide to sell these, let me know because I will definitely get a pair
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Andyw2100 said: ?

I've just been lurking in this thread because I find it interesting. This isn't anything I'd be interested in for myself, simply because I'm not a DIYer, and the potential issues down the road with Tesla, etc. worry me. But reading the above, I do have an idea that might help you and some people out.

You could, conceivably, have an "A" and a "B" level of core exchange, couldn't you? So units that come in that meet your very high standards are replaced with similar units. Units that don't quite meet those standard, but are pretty close get the "B" rating, and are then replaced with other "B" units.

If you started doing enough of these, you could even have a price for someone who sent in a "B" core to upgrade to an "A" unit, and a "discount" for someone who turned in an "A" unit, but who would be satisfied getting the new lights back in a "B", to keep your inventory even.

Depending on how much variation there is in these things, you could also add grades, if needed, and if the volume justified it.

Just some thoughts.

Good luck with what you are doing. It looks like you'll be providing a much needed and in-demand service!
Click to expand...

Thanks for sharing, I like that idea and it makes sense to differentiate the different lens conditions. Ideally any core exchange received would be in good enough condition for the next customer but with a high standard of trade-in quality I am not sure how realistic that would be. Even if the customer would be happy receiving headlights in very average condition, being completely selfish, that wouldn't be OK with me as I prefer my product to be held to higher standards.

I looked into sourcing new lenses on their own and unfortunately Tesla only sells headlights as a complete unit, which is a bummer as swapping the lenses would essentially make every headlight that I modify, appear new! There is also lens restoration and possibly having replacement lenses made but as of now I would prefer to not deal with the added time and labor involved with lens restoration and having replacement lenses made would take a lot of money and raise some quality issues.

It will be interesting to see how the core exchange works out, I have a feeling that a majority of Model S owners who would be interested in an upgrade like this will have well cared for headlights and also expect a top-notch product.

Evan
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All I can say is amazing! You're doing us all a great favor showing the options. We should all be very grateful for the time you've committed to preparing these very informative posts.

I love the black demon eye. That's what I'll want done to mine.
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Jool said: ?

Loving all this information! When you decide to sell these, let me know because I will definitely get a pair
Click to expand...

artsci said: ?

All I can say is amazing! You're doing us all a great favor showing the options. We should all be very grateful for the time you've committed to preparing these very informative posts.

I love the black demon eye. That's what I'll want done to mine.
Click to expand...

There is a lot of cool modifications which can be made to headlights and it is good to explain the cause and effect as well as the benefits and downsides of each!

I think the black demon eye will look killer on the model S.
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I received another set of Model S headlights and took the opportunity to take some before and after photos of the turn signal performance.

The unmodified headlight not only has the transparent "belly" of the turn signal diffuser which scavenges turn signal light but also has a very silver (textured chrome?) finish on the housing which further reflects the light. The light bleeds from diffuser and bounces around in the housing and most of the headlight appears to be reflecting light during turn signal operation. The end results is a rather sloppy looking but very effective turn signal.

The black paint on the bottom of the diffuser limits escaping light and the black paint on the housing keeps reflection to a minimum, light output is more controlled but not as effective compared to the unmodified oem unit.

Here are some pictures at different angles and exposures.

Evan

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Amazing the difference black makes.
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I'm interested in an exchange when you are up to producing units! Thanks!!!
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This is so awesome! I am in Ladera and sign me up. I have blacked out chrome on Dark grey, this would totally complete the look.
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Had a nice chat today with a local 3D scanning and printing business. I am familiar with the technology on the most basic level so it is cool to better learn what is involved and possible with the process, fascinating technology and I am looking forward to utilizing it in this headlight build!

Here are some pics of the shop!

Evan

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I did some more testing on the "beta" headlights. I frosted the turn signal to see how much that would change visibility/performance and also changed the demon eye from White to Black. Both changes yielded positive results.

Projector after receiving the black "demon eye"

Previously the lens holder was left unpainted (raw aluminum) and I found it to be distracting...

...it looks much better black and gives the headlight a cleaner and more cohesive appearance.

Up next was frosting the turn signal. I am a huge fan of this modification both for the aesthetics is can offer in addition to the function. The Model S was a great candidate since it has a high powered LED signal and the issue was most of the light is directed forward and after painting the belly of the turn signal black, output towards the side was limited. The frosting increases light diffusion and makes the light more visible from all angles, there was no noticeable decrease in turn signal performance while viewing the headlight from the front.
In addition, the oem DRL has a textured surface with a satin/matte finish from the factory where the turn signal had a gloss finish, frosting the turn signal and leaving the DRL as-is makes appearance of the two diffusers more uniform.

LEFT: Frosted RIGHT: Oem

Frosted

Frosted in direct sunlight

DRL and signal now have a similar finish #Details

Still plenty of power out the front

LEFT: Frosted RIGHT: Oem

Exposure dropped, frosted signal has better intensity

Before and After on the same headlight

Good looking headlight, this is how I would build one for my car ...if I owned a Tesla

I also received another set of Model S headlights, here is the oem packaging. The headlights are suspended in what I would describe as a "heavy duty seran-wrap trampoline" lol

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I've still got my OEM stock headlights that I took off when putting on the blacked out ones. If anyone is interested in purchasing them for this project, let me know. They are in perfect and working condition. I thought it would be fun keeping them in case I wanted to have them put back on if I didn't like the blacked out look, but I love it and can't imagine stock heights again.
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Also, I really love the black demon eye! I finally got my new wheels that go with the blacked out light housing, and match the lines of the car better. Going to make a thread after I take decent pics. I thought after my new wheels I'd have the perfect set up and everything I wanted, but now I feel like I'm missing the black demon eye! Damn you
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The ISS headlight test results indicate what a very poor job most manufacturers are doing with headlight design. BMW 3 series was worse (the Ultimate Driving Machine unless one is depending on seeing the road at night). Prius was best. But what was most shocking is that most auto brands didn't make the grade. Tesla was not among those tested but my guess is that it would not have fared very well. So your mods Evan will not only improve aesthetics but much more importantly, safety.
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Nice mod!
Can't wait to see it on the model s.
Depending on how it looks on the model s and price, I might be interested in this!
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let me know who much im ready to place an order
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Wow! I love what you've done @ucsbwsr!!! Darn sexy headlights! I'd most definitely buy them!
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AMPd said: ?

Nice mod!
Can't wait to see it on the model s.
Depending on how it looks on the model s and price, I might be interested in this!
Click to expand...

Da0ne said: ?

let me know who much im ready to place an order
Click to expand...

I should have some more information in the near future

benjiejr said: ?

Wow! I love what you've done @ucsbwsr!!! Darn sexy headlights! I'd most definitely buy them!
Click to expand...

Thanks, if you think the housings look sexy wait until you see the output!

Evan
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That box is a Korrvu Suspension Box. In that size they're almost impossible to buy anywhere so I'm guessing Tesla or its headlamp manufacturer had them custom made by Korrvu. The concept is simple -- stretch polyurethane film (probably 2 or 3 mils) glued to a cardboard opening that sits under and on top of the headlamp, with the whole assembly fitting into a right-sized shipping box. Easy to replicate, so i'll be making my own to ship the headlamps to you. Beats all the foam and bubble wrap solutions by a mile. And it's far less work. Better yet they're reusable.

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@SPXMike was kind enough to lend me his car for the weekend. It was a great help as I could further familiarize myself with the front end of the Model S, confirm some spacial limitations, and take some photos of these modified headlights on his car, both "glamour" daytime shots and the all-important output shots. Thanks again Mike!

I experimented with a more powerful 50w ballast. My initial thought was to mount this inside the headlight to make the complete unit PNP but although the ballast would physically fit inside, I opted against it as if there was ever an issue with it down the road, the entire headlight assembly would need to be separated (lens from housing) to access the ballast. Not ideal.

After assessing the cavity where the headlight resides I came up with a decent solution; the ballast has a bracket and it mounted to the chassis on a stud/10mm nut combo that is shared with a relay, the ballast is only mounted using 1 of its 8 possible mounting points but unless you plan on driving your Model S like an off-road trophy truck, it should be adequately secure. The ballast can be mounted in a matter of seconds and is easily accessible with the headlight mounted, the input and output connections are also easy to reach so install and removal is very easy.

I drilled a hole in the side of the housing to allow for the ballast input and output wires to pass through. 50w ballast input is soldered to the oem input, heat shrinked, and zip-tied for added security. Input and output wires are also zip-tied on each side of the housing seal to prevent any unwanted tension.

Ballast input and output/ignitor

Soldered input connection

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First batch of photos are the Before & After. More pics later

Testing operation

Trim on, black headlights are hard to photograph once the lens is installed due to reflection so I had take at least one pic without the lens installed.

Lights off

Lights on

Oem is a reflective mess

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Well, I've never seen so may headlights in one place until I walked into @ucsbwsr's garage! Admittedly I was a bit nervous having Evan do exploratory surgery on my car, but it was for a good cause and as you can see from Evan's posts he is very professional about this. What specifically intrigued me about this project is, besides the look (goes great with the Obsidian Black Metallic and the grey 21" turbines), my wife has an RX350 and one of the first things I noticed when we bought that Lexus several years ago were the headlights. Very bright with a crisp cutoff along the upper edge. Also I live in a rural area with no streetlamps and lots of critters so I appreciate good headlights when I'm driving home.

Evan put my original lights back in as the mod isn't quite ready for prime time. He needs to get a mounting bracket designed and printed. Also I'm interested in Morimoto projector options using D2S bulbs.

We all value creativity, technical expertise, and the entrepreneurial mindset, and @ucsbwsr clearly has all that. Thank you for taking good care of my car, Evan, and I'll look forward to the new lights when you're ready.
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excellent thread!

This is bringing back some major emotions for me right now. Reminds me of the time I retrofitted the Q45 (Gatling Guns) into my car at the time ( I didnt do it for the output, I did it for the "wow" factor )

Great post

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SPXMike said: ?

Well, I've never seen so may headlights in one place until I walked into @ucsbwsr's garage! Admittedly I was a bit nervous having Evan do exploratory surgery on my car, but it was for a good cause and as you can see from Evan's posts he is very professional about this. What specifically intrigued me about this project is, besides the look (goes great with the Obsidian Black Metallic and the grey 21" turbines), my wife has an RX350 and one of the first things I noticed when we bought that Lexus several years ago were the headlights. Very bright with a crisp cutoff along the upper edge. Also I live in a rural area with no streetlamps and lots of critters so I appreciate good headlights when I'm driving home.

Evan put my original lights back in as the mod isn't quite ready for prime time. He needs to get a mounting bracket designed and printed. Also I'm interested in Morimoto projector options using D2S bulbs.

We all value creativity, technical expertise, and the entrepreneurial mindset, and @ucsbwsr clearly has all that. Thank you for taking good care of my car, Evan, and I'll look forward to the new lights when you're ready.
Click to expand...

Did you take any photos with the headlights on your car?
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@AMPd Please take a look at post #80 in this thread. Evan switched out the right headlamp but left the left OEM installed so you can see the contrast. How do you like it?
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Kinda looks like she got into a bar fight and got popped in the right eye... But I am definitely going with this mod (both headlights!) when I settle on a projector/ballast combination.
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SPXMike said: ?

@AMPd Please take a look at post #80 in this thread. Evan switched out the right headlamp but left the left OEM installed so you can see the contrast. How do you like it?
Click to expand...

Wow! Looks really nice!
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Here are some pictures featuring both modified headlights. For demonstration purposes I painted one projector with a black "demon eye" and the other with a white, it is fun (and effective) to see them side by side like this. As a little recap, a demon eye is when the front side of the projector's internal shield is painted, since it is facing forward this paint color can be shown through the lens and because of the lens' optics the entire lens will appear that color (imagine looking at someone holding a magnifying glass away from their face which amplifies their features). A demon is not effective at all viewing angles, some you won't notice, some you will, and at others it can appear almost as it is illuminated. Ambient light that makes it into the projector will also help the demon eye pop.
Other than the demon eye the headlights are identical here are the specs on this particular build:

- Modified Lexus RX350 Bi-Xenon Projectors: Clear lens swap, tuning, and a demon eyes (white/black)
- Morimoto xb55 50w Ballasts
- Morimoto xb35 5k Bulbs
- Satin Black Housing
- Frosted Turn Signals

Photos were quite tricky as I often found myself in the reflection of a black car with black headlights, it was a little bit of a struggle-city capturing the photos I wanted without my ugly mug in the your face.

Most photos will have comments,
Evan

LEFT: Black Demon Eye RIGHT: White Demon Eye In direct sunlight

Black

White

DRLs on

This is a white demon eye in full effect! Even in a shadow is still pops white. The front of the shield on the RX350 is very smooth and helps create that uniform look of the white paint.

So creepy

Annie approves ...for food.

Close up

Notice how the demon eye is not noticeable at this angle or light level

Good looking Model S!

It is nearly dusk and the white demon eye pops up again

DRLs

Turn Signal

HID

Get it?

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Nighttime

Output

I was doing an experimental shield modification on the passenger-side projector and it didn't turn out as expected so that is why the cutoff is flared a little on the right projector, normally it would look exactly like the output on the left.

Short distance pictures to show beam layout (HID + LED fogs)

Projector only

Projector + Fog They fit well together

HID + Cornering Light

HID + LED Fog + Cornering Light

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@ucsbwsr Will you just take my money already? lol These look ahhhhh-mazing!! I thought I would like the black demon eye better to go with my blackout, but that white demon eye is really growing on me!
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How about a white demon eye for those of us with white cars?
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i want to go with the black demon eyes with 6k bulbs on 50 watt ballast
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@ucsbwsr You took my car to a gas station?!? LOL!
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Totally Awesome! I have a white car that would look great with these!
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SPXMike said: ?

@ucsbwsr You took my car to a gas station?!? LOL!
Click to expand...

Your car has seen the dark side!

They look fantastic!

What about red demon eyes for those with an MC red model s, can that be done?
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Awesome stuff! I was reading into it when Unplugged Performance offered something similar, but wasn't specific when I asked them.

Also, do you have any upgrades in mind for the LED fogs? Perhaps using a different color (3k, yellow fogs)? Brighter, wider spread?
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benjiejr said: ?

@ucsbwsr Will you just take my money already? lol These look ahhhhh-mazing!! I thought I would like the black demon eye better to go with my blackout, but that white demon eye is really growing on me!
Click to expand...

I thought I was going to prefer the black demon eye as well but on this particular projector the white demon eye looks REALLY good, not all projectors would be as effective as this one due to the interior design.

doctorwho said: ?

How about a white demon eye for those of us with white cars?
Click to expand...

Ingineer said: ?

Totally Awesome! I have a white car that would look great with these!
Click to expand...

Yes, these would look especially good on a white car. Operation Storm Trooper, these are not the droids you are looking for but these definitely are the headlights you are looking for!

SPXMike said: ?

@ucsbwsr You took my car to a gas station?!? LOL!
Click to expand...

I pulled in to clean the windshield, when I realized an EV was at a gas station I felt obligated to take a photo.

AMPd said: ?

What about red demon eyes for those with an MC red model s, can that be done?
Click to expand...

I suggest staying away from colors, especially red, blue, and green. It is illegal to have non-amber colored lights on the front of your car, as I understand it is pertains to illuminated lights so I don't think the passive demon eye is applicable but regardless I error on the side of caution and can't recommend it.

Also, the shield is subjected to very high heat from the HID bulb so I only use high-temp paint, so where red is possible, it likely wouldn't be a perfect color match if that is what you were thinking. I have an IR thermometer gun on the way and will do some testing to see what the actual temps are and if it is possible to use a wider variety of paints.

Evan
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Nismode said: ?

Awesome stuff! I was reading into it when Unplugged Performance offered something similar, but wasn't specific when I asked them.

Also, do you have any upgrades in mind for the LED fogs? Perhaps using a different color (3k, yellow fogs)? Brighter, wider spread?
Click to expand...

Funny you mention the fogs, just yesterday I purchased a set to tinker on. After seeing the backside of the units it looks like they may be sealed in a similar way to the headlights with clips and permaseal so I will see if i can crack them open. Honestly the units perform well for their intended function. The projector fogs have a decent beam pattern and intensity (especially considering there is only 1 projector per side), the cornering light is also effective. I am not really sure why they put those vertical LED tubes in there, they look cheap and very out of place.

I don't think any major fog-light upgrades will be worth the effort but I plan to try look into a few things.

- Confirm the LEDs behind the reflector are indeed amber, if so I will look into having some clear and smoked-clear reflectors made, it will help clean up the look of the front end. I have a hidden agenda to kill all amber reflectors on all cars, I can't stand them.
- Black out the chrome on the cornering light that isn't used for reflection. There are 2 LEDs and 2-4 reflective "shelves" which throw the light out to the side but there is some other chrome that can be deleted without compromising function. The question is if its worth the hassle as it might be tricky to strip the chrome prior to paint without damaging the rest of the chrome, TBD.
- I would love to delete the LED tube but I hate killing function, then again it is not like that little tube is going to make-or-break anyone seeing you at night, when it is illuminated your headlights, dimmed-DRLs, and amber marking light are all on.

Regarding Unplugged, I know the service includes paint and a clear lens upgrade with an etched logo, beyond that I don't know what is included. Interestingly, if you look at their upgraded front bumper, they mount the fog lights upside down!

Evan
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SPXMike said: ?

Also I'm interested in Morimoto projector options using D2S bulbs.
Click to expand...

Evan, SPX's comment here raises a question for me. Do the Morimoto projectors provide advantages over the Lexus RX350 Bi-Xenon Projectors? In other words do they provide even better performance?
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I was thinking of something like that.
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AMPd said: ?

I was thinking of something like that.
Click to expand...

Take note that the M5 pictured above has red demon eye and shroud to match the body color, it amplifies the effect.

My statement stands regarding the potential problems red on the front of the car can cause but a red demon eye is certainly possible, Red is an attention grabbing color so, in my opinion, whether it looks good or not is all about application.

Evan
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artsci said: ?

Evan, SPX's comment here raises a question for me. Do the Morimoto projectors provide advantages over the Lexus RX350 Bi-Xenon Projectors? In other words do they provide even better performance?
Click to expand...

This is a good time to paint a picture of the HID projector world...

Projectors can be broken down into 2 parts, OEM and Aftermarket.

Within the OEM world there are some exceptions to the rules but generally Japanese car manufacturers like Honda/Acura, Toyota/Subaru/Lexus, and Nissan/Infiniti are equipped with very high quality projectors made by Koito and Stanley. Porsche and Land Rover have some decent projectors but most other German brands don't have much to offer. American car companies also don't bring much to the table.

There are many aftermarket options but the only one I trust (most headlight enthusiasts would agree) is Morimoto.

I am finalizing my bracket design for the headlights and have a good idea what the projector options will be. In the near future I will take some output shots comparing the options. Headlight output can be subjective and also vary on application so it will be good to see what each has to offer and know how it can benefit you.

Evan
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Busting out the arts-n-crafts skills for a rough bracket sketch

Here is a picture showing various projector sizes. From right to left: Acura TL 3G, Porsche 997, Lexus RX350, Model S.
The TL and 997are some of the largest on the market and have very large external solenoids that make them challenging to fit. I gave 110% effort trying to think of creative ways to make them fit as both are top performers but in the end it simply wasn't possible.

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ucsbwsr said: ?

- Confirm the LEDs behind the reflector are indeed amber, if so I will look into having some clear and smoked-clear reflectors made, it will help clean up the look of the front end. I have a hidden agenda to kill all amber reflectors on all cars, I can't stand them.
Click to expand...

I'm pretty sure US DOT regs require amber side reflectors of some minimum area, making clear/smoke reflector conversions illegal. That being said, I hate amber reflectors too. I replaced the amber with clears on my E46 M3 the day I got it, and never had any legal issues the entire 12 years I owned the car. One of the things I like about the Model S's lighting system is that they've hidden the amber reflector pretty well (minimal area, buried and low to limit the angles at which you can see it), so I don't feel much of a need to eliminate it.
Regarding the LED light tubes, I believe those are the running/front parking lights, for those folks that turn off the DRLs at night.
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CzTom said: ?

I'm pretty sure US DOT regs require amber side reflectors of some minimum area, making clear/smoke reflector conversions illegal. That being said, I hate amber reflectors too. I replaced the amber with clears on my E46 M3 the day I got it, and never had any legal issues the entire 12 years I owned the car. One of the things I like about the Model S's lighting system is that they've hidden the amber reflector pretty well (minimal area, buried and low to limit the angles at which you can see it), so I don't feel much of a need to eliminate it.
Regarding the LED light tubes, I believe those are the running/front parking lights, for those folks that turn off the DRLs at night.
Click to expand...

I agree Tesla did a nice job tucking it away. Yes legally any color emitted or reflected on the front of the car must be amber. Perhaps a very light tint on the amber reflector is a "safer" solution, although some lightly tinted clear reflectors would be aesthetically-ideal. The marker LEDs behind the reflector also emit amber which is as I had hoped.

Interesting about the DRLs and their ability to be turned off. I remember seeing it as an option in the controls but I don't recall 1 Model S on the road without the DRLs on, perhaps I overlook it. Seems like locking the normal DRLs "on" but at higher/lower voltage and omitting the 2ndary running/parking light is a cleaner solution. The main DRLs are so effective and look so good.

Evan
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More goodies arrived at the lab

That didn't take long

Board

Corner light LEDs

Amber LEDs located behind reflector

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Stay tuned ... LED headlights may be introduced on the Model S next week.
Updated Tesla Model S with more features, higher price coming soon - Roadshow

The most immediate change, according to our sources, will be a slight visual refresh on the nose.

It won't look exactly like the Model X or Model 3, we're told, but it will bring the car closer to the frontal treatments of those cars.

LED headlights will also provide a cleaner look up front, while some additional paint colors will join the configurator.

On the inside, the Model S will move to the same front seats found in the Model X, meaning ventilation will be an option. The car will receive some new interior storage compartments, including pockets in the door -- an addition current owners will appreciate.

We're told that Tesla is cleaning out the last of the previous generation's production parts now and that the refreshed Model S could debut as early as next week. Our sources say a price increase will come with these updates, but the amount remains to be seen.
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Hopefully Tesla (or Visteon) did their research and are producing an LED headlight that isn't sub-par like most LED units currently on the market.

Evan
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While many on this site have been pushing for LED headlamps, based on the research I've done it's highly likely that their performance will be worse or at best no better than HIDs. If Tesla goes forward with LEDs, in terms of performance it could be a step backwards. Yeah, it will be cool to say one has LED headlamps, but when it comes to headlamps, for many of us performance is the only standard that counts. Cool be damned.

If Tesla really wants to jump ahead they should skip over LEDs and go straight to lasers, which perform much better than any other technology. But they cost a small bundle -- a $10,000 option on the Audi I think.

I'm betting that if Tesla does include LED headlamps in the Model S upgrade their performance will be no better or perhaps worse than the current HIDs, in other words a step back. If one wants superior performance I'm also betting the Evan's upgrade is the way to go.
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Yeah, I see that others have beat me to questioning why some are excited about LED headlamps. No thanks.
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artsci said: ?

While many on this site have been pushing for LED headlamps, based on the research I've done it's highly likely that their performance will be worse or at best no better than HIDs. If Tesla goes forward with LEDs, in terms of performance it could be a step backwards. Yeah, it will be cool to say one has LED headlamps, but when it comes to headlamps, for many of us performance is the only standard that counts. Cool be damned.

If Tesla really wants to jump ahead they should skip over LEDs and go straight to lasers, which perform much better than any other technology. But they cost a small bundle -- a $10,000 option on the Audi I think.

I'm betting that if Tesla does include LED headlamps in the Model S upgrade their performance will be no better or perhaps worse than the current HIDs, in other words a step back. If one wants superior performance I'm also betting the Evan's upgrade is the way to go.
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Edmond said: ?

Yeah, I see that others have beat me to questioning why some are excited about LED headlamps. No thanks.
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I am a firm believer that LEDs will surpass HID in performance in terms of raw output but they are not there yet. LEDs have certain favorable characteristics like low power consumption and long life but their main edge over HIDs is the light control with matrix LEDs. This technology must be well executed to be effective but having multiple light outputs as opposed to one certainly has it's advantageous for keeping light where you need it and NOT in the face of opposing traffic. Effectiveness if based on how the factory lights are aimed and the software recognizing oncoming traffic. Properly aimed HID lights will seldomly blind oncoming traffic but the chances do increase in areas with hills and more frequent elevation changes.

There is a future for laser technology as it is such an efficient light engine (perhaps high-beam only) but I feel like it will be overkill for most common automotive applications and I think once LED technology is fine-tuned it will be ideal for road-going vehicles. Even if a laser can reach 3/4 or 1 mile, will the human eye be able to capitalize on that illumination? With the capability of modern LED light bars I don't foresee LED output being a handicap for the application, it is only a matter or making the diodes bright enough and cool-running enough for constant use and improving the intelligent "where you need it and where you don't" techonology.

Evan
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Back to the issue of upgrading the current HID lights, is it possible to have an upgrade kit for those of us outside the US or even a set of part numbers and detailed instructions?
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Those who are admonishing against the LED headlamps likely have not seen a direct comparison of the Model X LED lights over the Model S HID setup. The Model X lights perform much better than the stock HID setup, especially in back roads. A lot of this may have to do with the taller ride height as well as the directional cutoff.

From what I've seen, I love the diffused DRL look with the new Model S LED headlamp setup. Anyway to replicate this with the current projector setup?
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First of I would like to say excellent work, would love to do this to my current car, but I can't get myself to turn the on the button of my oven, I have however changed my vehicles lights from standard lights with projectors to HID's 35w 6000k to be exact, makes a huge difference.

here's hoping Tesla will start shipping to South Africa as soon as possible.

Secondly I think you meant from Left to Right in the picture?

Here is a picture showing various projector sizes. From right to left: Acura TL 3G, Porsche 997, Lexus RX350, Model S.
The TL and 997are some of the largest on the market and have very large external solenoids that make them challenging to fit. I gave 110% effort trying to think of creative ways to make them fit as both are top performers but in the end it simply wasn't possible.
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doctorwho said: ?

Back to the issue of upgrading the current HID lights, is it possible to have an upgrade kit for those of us outside the US or even a set of part numbers and detailed instructions?
Click to expand...

If you are asking if it is possible to have modified headlights shipped internationally, yes, that is possible depending on where you live and what the customs are. As of now I don't plan to offer a kit but most of the components used in the headlights are available online and tracking them down isn't difficult. If I didn't understand your question correctly, please clarify.

Nismode said: ?

Those who are admonishing against the LED headlamps likely have not seen a direct comparison of the Model X LED lights over the Model S HID setup. The Model X lights perform much better than the stock HID setup, especially in back roads. A lot of this may have to do with the taller ride height as well as the directional cutoff.

From what I've seen, I love the diffused DRL look with the new Model S LED headlamp setup. Anyway to replicate this with the current projector setup?
Click to expand...

Most LED vs HID discussion in this thread has been about the general performance which can be achieved with each, I don't think anyone was suggesting the Model S HID was as good or better than the Model X. I sure hope the LED headlights are a big step forward in performance as I think it is clear the oem HID system on the Model S is sub-par and leaves much room for improvement. It will be interesting to see how the Model S and X LED systems compare, I can't wait to get my hands on some to test!

For the frosting, it is possible to increase the amount of frost on the Model S DRL. There are different methods to achieve the look such as spray on "frosting" sprays and good ol' fashioned abrasion. It would take some research to find the technique(s) which give the desired result but it should be possible with additional time, labor, and materials.

I thought about frosting the DRL on this beta set of headlights but after frosting the turn signal I liked how the finish paired with the untouched DRL. On a future set I can try some light sanding in conjunction with spray frosting, I bet that would work fairly well.

Jeff4155 said: ?

First of I would like to say excellent work, would love to do this to my current car, but I can't get myself to turn the on the button of my oven, I have however changed my vehicles lights from standard lights with projectors to HID's 35w 6000k to be exact, makes a huge difference.
here's hoping Tesla will start shipping to South Africa as soon as possible.
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Retrofitting takes a leap of faith the first time you go for it. A lot at risk and a lot to gain!
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What I mean is that shipping to and from Australia is expensive for bulky items & it'll leave me without an (only) car for a while
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Nismode said: ?

Those who are admonishing against the LED headlamps likely have not seen a direct comparison of the Model X LED lights over the Model S HID setup. The Model X lights perform much better than the stock HID setup, especially in back roads. A lot of this may have to do with the taller ride height as well as the directional cutoff.
Click to expand...

The Model S HID setup sets a pretty low bar so the fact the the Model X LEDs are better is not something to write home about. I'm much more interested in the LED versus HID at the top level of performance.
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doctorwho said: ?

What I mean is that shipping to and from Australia is expensive for bulky items & it'll leave me without an (only) car for a while
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What I would like to do is source lights here in the US, build them, and then ship them to you. On your end you can either pay for the headlights complete OR, if you headlights qualify, can be sent back as a core exchange so the only time your car will be down is during the removal of your old and install of the new, which can be done in a few hours at a slow/cautious pace.

Conceptually this is what I would like to do.

Evan
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More information on the new LED units in the Model S. The base model includes LED as standard.
It appears that you will have to order the $3,000K premium package to get the 3 position adaptive lighting.

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Surprising that the adaptive feature is such a premium. I wonder if the "adaptive feature" is a firmware update, lol.

I am interested to see if the adaptive feature is a LED-on LED-off matrix or if the LEDs swivel. Since there are 14 LEDS that indicates a matrix style adaptive system but that would also suggest that the base LED and adaptive LEDs are very different in design, it would make no sense to have 14 LEDs on the base headlight, hmmmmm.

Hopefully they release more info and better photos of the headlights, information seems pretty cryptic considering the official press release has occurred and face-lifted production has started.

At any rate, it looks like the LED lamps might benefit from some custom paint...

Evan
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ucsbwsr said: ?

What I would like to do is source lights here in the US, build them, and then ship them to you.
Click to expand...

Would the fact Australia are RHD change much?
I guess our lights are setup the reverse of the US lights?
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teslamotorclub

Thứ Ba, 27 tháng 12, 2016

Optimized Optics: High Performance Headlights, Improved Output & Improved Aesthetics part 1

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