I think we all (who own Roadsters) need to be pro-active and start brainstorming what will start failing and address the issue ahead of time while we can. Here are a couple of things I'm concerned about:
Rear CV axles - we need measurements of these when pulled, as much detail as possible. They don't match the Elise, I already tried matching it. Can our original failing one (when the time comes) be refurbished? I think so. Any precautions? We'll have to keep a close eye on the CV boot and look for cracks. Also spraying Aerospace Protectant 303 on it to condition the rubber will prolong the life of the boot. As long as the grease stays in there we'll be good to go for a while with these.
Contactor - I don't know what contactor is in there, but most likely that's not a Tesla specific thing and with our electrical / hardware knowledge we can get around that. Thing is once that starts pitting and deteriorating, the Roadster will start loosing power, cut out on you, throw error codes about the contractor open/closed position it doesn't like. I don't think this is a biggie but we should at least have a reference on hand.
BorgWarner eGearDrive Tranny - This one was somewhat mass produced for EVs but we have to watch out about the gear ratio, we're pretty unique that way. If a gear in there goes out we need to find something close already made (good luck) or have a hardened gear machined for us.
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BorgWarner eGeardrive Products)
CF body parts - can be custom made.
Headlights - Don't know if the 3D printer will help us here, but if not we can try to contact the original OEM manufacturer but need to have "x" amount made to make it worthwhile for them. There are plastics companies out there who can work with a mold and make what you want, so this most likely could be pieced together.
**My BIGGEST concern is the "memory"/Flash area that keeps our firmware and the Unix OS running in our VMS. I'm an expert there, use to do 2nd source testing in that area for Amazon's Kindle (stress testing, wear levels, failure rates, etc). Flash/Nand has a given shelf read / write life. Its a vulnerable part over time with use. The flash on our Roadsters WILL die, that's a given, we need to address that (the part), but also work together to archive the running software image in our Roadsters. We for sure need to start "hacking" into our unix (VMS) system and preserve our current firmware image or ask Tesla nicely to guarantee the source code is being kept safe (multiple SVN repositories) and available at our access when we need it. [I don't have confidence in the archive and preservation of the code-source as voiced from in Tesla internal sources, so we need to understand this (especially to Elon) and send a strong message this to be protected / preserved, its the pure roots and history of Telsa!]. When this code goes dead/away, so do our Roadsters. I mark this as a #1 Priority in my opinion coming from hardware/software/embedded system background.***