HID Projector Lamps

[Whaleboy]

Well, like I originally threatened I have finished mounting E46 (audi/bmw) projectors with HID bulbs/ballasts. The projector shrouds aren't complete yet, but the projectors are at least installed. It's simply a modification to the reflector housing so it can still utilize the headlight casings own leveling bolts.

The nice thing about this setup is I won't have to worry about casting off glare from the reflectors of a traditional H4 HID setup (not that its terribly bad in the first place, and can be remedied with a proper glare shield), and I get that pretty vibrant semi-purple flicker when you view the fresnel lens at just the right angle.

I did fabricate a custom cut-off shield on the projectors themselves to accentuate the effect.

Here's my step by step, though I doubt anyone would be interested in doing the same.

The projector:

http://www.vehicross.info/gallery/data/500/114headlights1.jpg

Opening up the headlight assembly (via boiling water)

http://www.vehicross.info/gallery/data/500/114headlights2.jpg

More of the assembly open:

http://www.vehicross.info/gallery/data/500/114headlights3.jpg

Cutting the opening for the projector:

http://www.vehicross.info/gallery/data/500/114headlights4.jpg

Test fit of the projector in the reflector:

http://www.vehicross.info/gallery/data/500/114headlights5.jpg

I cut out and reshape several plastic mounts from an electrical housing for the projector to mount to on top the reflector housing.

http://www.vehicross.info/gallery/data/500/114headlights6.jpg

Using high-strength plastic epoxy and sanding the areas to be applied, I glued the plastic mounts to the reflector.

http://www.vehicross.info/gallery/data/500/114headlights7.jpg

The projector mounted/screwed to the plastic shafts.

http://www.vehicross.info/gallery/data/500/114headlights8.jpg

Another view of the projector mounted to the reflector housing.

http://www.vehicross.info/gallery/data/500/114headlights9.jpg

All powered up to the ballast, testing heat/operation.

http://www.vehicross.info/gallery/data/500/114headlights10.jpg

projector light hitting the wall. the camera is a little overwhelmed so you can't really see the distinct cutoff. Notice there is no light hitting above the cut off.

http://www.vehicross.info/gallery/data/500/114headlights11.jpg

Reflector remounted back into headlight assembly. Ready for shroud around projector, then to be resealed with clear cover.

http://www.vehicross.info/gallery/data/500/114headlights12.jpg