technical
Custom Headlights: How We Manufacture Unique Optics
Headlights are the eyes of a classic car. When they are damaged or impossible to find, at Gredos Garage we manufacture them bespoke using modern technology.
6 min read
The headlights of a classic car are one of the elements that most define its personality. Yet they are also among the hardest components to find in good condition: reflectors deteriorate, lenses cloud and internal mechanisms fail. At Gredos Garage we have developed the capability to manufacture bespoke optics when originals are unavailable.
Original Headlight Restoration
Whenever possible we opt to restore the original optics. The process includes: complete headlight disassembly, cleaning and polishing the parabolic reflector, re-silvering when the reflective coating is deteriorated, polishing or replacing the lens, overhauling the adjustment mechanism and resealing with new gaskets.
Custom Lens Manufacture
When the original lens is broken or impossible to source, we make it. We use high-transparency optical acrylic CNC-machined to replicate the exact geometry of the original lens, including the diffusion patterns that direct the light beam. For complex curved lenses we fabricate moulds and thermoform the material.
Custom Reflectors
Reflectors are manufactured from CNC-turned aluminium with the exact parabola required for each application. They are then mirror-polished and coated with vaporised aluminium and a protective sealant. The result is a reflector with luminous efficiency equal to or exceeding the original.
Discreet LED Conversions
For those wanting greater safety without sacrificing original aesthetics, we offer LED conversions that keep the external headlight appearance intact while providing vastly superior illumination. These conversions are fully reversible to maintain vehicle originality for concours events.
Special Cases
We have manufactured optics for models as diverse as a Citroën DS, a Lancia Aurelia and an Aston Martin DB5. Each project is a technical challenge we embrace with enthusiasm. At Gredos Garage, restoring your classic's sight is one of our specialities.