HowTo: P11 HID Retrofit (56k warning)

[Koojo]

I've been reading up a lot on HID's and retrofits, and decided to start a project of my own. I want to thank Eric for the retrofit inspiration.
I have Audi RS6 bixenon projectors (3" lens), Maxima ballasts/ignitors and Phillips D2S 4300K bulbs.

I just received an extra set of headlights and also the projectors in the mail today so started to do some stuff. Here are some pics from today:
RS6 bixenon projector


Rear view


3" lens (I'm surprised that the picture shows a lot of fresnles..because in reality they are really hard to see...lens looks almost clear)


Projector with lens housing removed..notice the shield mechanism (this is the position during low beams)


Position during high beams


I added 2 #8 (total width 1/16") washers in each of the top two screws to produce more blue color in the cutoff line instead of yellow...


See what I mean...looks damn clear


View from the bulb location


Lens housing removed


Test fitting the projector inside the reflector housing




The projectors are rather big, but I will make them fit. I'll have to cut up a bunch of the headlight reflector, but that doesn't really matter, because I'll be painting it dark grey in the future anyway.
I'll post updates as they come.

[P11jdnkola27]

How much would this cost?

[rmyc]

MONEY!!!.. really like how that sheild works.. pretty interesting

[Koojo]

Originally Posted by P11jdnkola27

How much would this cost?

RS6 Bixenon Projectors $180 shipped
Phillips D2S Bulbs $80 shipped (new)
Maxima ballasts/ignitors $150 shipped
Wiring/relays/misc probably about $30

(I also bought a second set of headlights from a member here, but I will sell the other set once I'm done, so I'm not factoring in the price of the 2nd set of headlights)

[Mxer683]

Thats a really nice set up. All these retrofits mite inspire me to do one myself?

[Ericdd]

Originally Posted by Koojo

RS6 Bixenon Projectors $180 shipped
Phillips D2S Bulbs $80 shipped (new)
Maxima ballasts/ignitors $150 shipped
Wiring/relays/misc probably about $30

(I also bought a second set of headlights from a member here, but I will sell the other set once I'm done, so I'm not factoring in the price of the 2nd set of headlights)

damn I got off easy, I spent about that much with an extra set of headlights. good luck keep the pictures coming

[LoSt]

Nice, glad to see hooking up HIDs the CORRECT way is catching on! Keep us posted!!!

[Koojo]

I started working on installing the projector. I highly recommend a dremel tool, not sure how else this can be done...anyway here are the pics:

I started cutting out a circle in the back of the reflector where the rear of thw projector would sit




I fitted the reflector into the headlight and put the projector in, but I still needed to cut out more


It still didn't fit right so I kept on cutting..here is the final cut of the reflector


I made it so there is about a centimeter of play left and right so when I aim the projectors it won't be a problem.




I'm going to attach bolts here and drill two holes in the reflector, and mount the projectors that way (as well as some jb weld)


I also have about a centimeter of play up and down to make aiming easy.


Back


Flush with the back of the headlight housing...I didn't have to cut the housing at all.


Now I need to start working on the second headlight

[rmyc]

nice, on the back find a peice of pvc that fit in the H4 rubber outer seal
-run the wires through the pvc and seal it with epoxy

and you should now have a water sealed headlight

[G20t99]

im amazed that all fit in there without cutting the back out. How close will the plastic outer cover be to the projector lens???

[Koojo]

Finished the other headlight...it went really quick. I just measured the cut lines from the finished headlight and used them on the other one.

Money shot


very BLURY picture...I tried not using a flash. The lenses that came with these headlights had a bunch of rock chips on them...so I'm going to swap my headlight lenses in there later on.


Ya I was surprised that the whole projector fit in there like that. With the outer cover put back, there will be about 3/4-1" of space between the end of the projector lens and the cover. So plenty of space. I like how the projector is more toward the front of the headlight, so I won't loose much foreground light.

rmyc, I'm thinking of just making holes in the rubber gromet and running the wires through that. The wires will be heat shrunk and stuff.

[Ericdd]

wow I originally though your projectors were bigger, but they are way smaller than mine. everything looks real good, you're moving right along. You'll probably have yours in befre me

Originally Posted by Koojo

Finished the other headlight...it went really quick. I just measured the cut lines from the finished headlight and used them on the other one.

Money shot


very BLURY picture...I tried not using a flash. The lenses that came with these headlights had a bunch of rock chips on them...so I'm going to swap my headlight lenses in there later on.


Ya I was surprised that the whole projector fit in there like that. With the outer cover put back, there will be about 3/4-1" of space between the end of the projector lens and the cover. So plenty of space. I like how the projector is more toward the front of the headlight, so I won't loose much foreground light.

rmyc, I'm thinking of just making holes in the rubber gromet and running the wires through that. The wires will be heat shrunk and stuff.

[hiimj0ne]

Oh man, can't wait to see them on the ride! Looks good, now only if I had the time and money to do something like this.

[rmyc]

Nice, and ppl thought Eric had alot of time on his hands..

[rmyc]

Koojo you better do some angle eyes.. easy to build

[Ericdd]

I'm not a fan of them on any other car but a BMW but here's a write up if you are

http://www.diyautomods.com/forum/showthread.php?t=8

[Koojo]

Nah no angel eyes here either....they stay on the 5 series

[vsamoylov]

retrofits are always fun. maybe one day i will do one.

[lay2ie]

Hey Koojo, did you put it on the car and adjust the aiming of the cut off's yet? If so please snap some shots

[Koojo]

No I haven't yet. I'm waiting for the bulbs to come in in a few days and also the stuff for the wiring harness. Once I have the harness all done, I'm going to try it all out, make sure it all works, and then aim them. After I have a good idea of how the projectors have to be positioned, I will need to permanently attach them, make some shrouds, bezels and it should all be set. I'm not driving the P11 until spring time anyway, so I shouldn't be rushing...but I'm kind of excited to get it all done.