so i got this vert a couple of weeks ago and it came with these crappy aftermarket headlights. i tried my best to make it look a bit decent (without spending too much cash) by spraying the internals matte black. it looked ok but just bought me time to get the originals and 'pimp' it out.
also, being used to driving with quad xenons (in my E90) i decided to do the same with these lights. so here goes...
first i stripped out the one side headlight completely and removed the OEM halogen projector. to obtain a smooth flat surface i broke off the tabs and filed it down.
i then measured accurately the existing mounting hole centres and the new MH1 projector hole centres. i superimposed them the two while keeping the centre point the same and made up an adapter plate from 3mm thermosetting plastic sheet. i drew these on AutoDesk Inventor 2013 and plotted it out with scale 1:1. i them used this as a template.
the finished adapter plate. not too shabby considering i did the whole thing with a dremel. i wanted to send them for laser cutting but could not wait and also it would have added a lot to the cost.
i then did a trial mount with the projector before i went and bought the right size bolts, washers and nyloc nuts.
i then modified a ZKW (e36) shroud to fit over the projector to complete the aesthetics.
while modifying the shroud i figured out that to make it fit properly onto the MH1 projector i had to trim the plastic threaded pieces that held the OEM projector. i cut each one short by 5mm.
after being happy with the outer side (old dipped driving lights) i then tackled the inner side (old brights). i marked out a circle just smaller than the projector diameter. it is better to cut small and then grind or file to suit than to cut big and mess it up.
i then trial fitted the other MH1 projector into the cut hole and marked where the solenoid for the shutter would go through. i cut about 3mm on each side of the solenoid to allow for rotational adjustment before final mounting.
after aligning the projector in the hole, i used this putty to firmly mount it to the headlight housing. the bond is absolutely strong!!!
here are a few pics with both projectors mounted and before being sprayed matte black
i then masked the projector lens and sprayed it with this. i used the same on the e90 headlight internals and they are still 100%
here are some pics of the almost complete RHS headlight housing sprayed matte black
TO BE CONTINUED . . .
also, being used to driving with quad xenons (in my E90) i decided to do the same with these lights. so here goes...
first i stripped out the one side headlight completely and removed the OEM halogen projector. to obtain a smooth flat surface i broke off the tabs and filed it down.
i then measured accurately the existing mounting hole centres and the new MH1 projector hole centres. i superimposed them the two while keeping the centre point the same and made up an adapter plate from 3mm thermosetting plastic sheet. i drew these on AutoDesk Inventor 2013 and plotted it out with scale 1:1. i them used this as a template.
the finished adapter plate. not too shabby considering i did the whole thing with a dremel. i wanted to send them for laser cutting but could not wait and also it would have added a lot to the cost.
i then did a trial mount with the projector before i went and bought the right size bolts, washers and nyloc nuts.
i then modified a ZKW (e36) shroud to fit over the projector to complete the aesthetics.
while modifying the shroud i figured out that to make it fit properly onto the MH1 projector i had to trim the plastic threaded pieces that held the OEM projector. i cut each one short by 5mm.
after being happy with the outer side (old dipped driving lights) i then tackled the inner side (old brights). i marked out a circle just smaller than the projector diameter. it is better to cut small and then grind or file to suit than to cut big and mess it up.
i then trial fitted the other MH1 projector into the cut hole and marked where the solenoid for the shutter would go through. i cut about 3mm on each side of the solenoid to allow for rotational adjustment before final mounting.
after aligning the projector in the hole, i used this putty to firmly mount it to the headlight housing. the bond is absolutely strong!!!
here are a few pics with both projectors mounted and before being sprayed matte black
i then masked the projector lens and sprayed it with this. i used the same on the e90 headlight internals and they are still 100%
here are some pics of the almost complete RHS headlight housing sprayed matte black
TO BE CONTINUED . . .
raise:
