US Spec to Euro Spec 2003 Headlight Redo (DJ Auto Lenses) - BMW M5 Forum and M6 Forums
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post #1 of 18 Old 1st January 2016, 08:46 PM Thread Starter
Dking078
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US Spec to Euro Spec 2003 Headlight Redo (DJ Auto Lenses)

I felt it would be a bit worthwhile to cross post this since alot have inquire about using DJ auto lens on their cars.

I had received some US spec headlights for experimenting. Lenses were trash and adjusters were long gone, in addition to being 2003 permasealed, not much hope was out there for them aside from a nice looking trash can or $$$ in repairing and cross country shipping .

Lo and behold, they fell into my lap and i decided to see what crazy things I could do.

The plan for these lights was DJ auto euro spec lenses and new adjusters, along with a butyl based sealant so they can be baked open in the future if desired.

Overall the project was a success, right now I have them on the car for rain / moisture testing of the sealant. As for the DJ auto lens itself, I'd give it an A- in fit and finish. looks great, the side rubber gasket is a bit stretchy, but that may be because it's brand new vs the 13 year old ones on my normal set. I could also do without the top circle cap, but nothing wrong with it otherwise, just personal preference.

How I got them...Not too good



The lens itself was demelled off...It was about 30 disks between the two lights, and a couple facial near misses from exploding ones


Free'd from 2003 spec hell! Not shown, but cleaning the channels of the left over sealant was pretty fun! I had made a few mess ups by splitting the outer housing from using too much force, but it was nothing my trim refurbing experience couldn't fix/reinforce.


The ugly old adjusters.



New adjusters and butyl sealant... apparently not that easy to find in the US.




Almost there.


Cleaned up the outer housings and all rubber gaskets.


All Finished! I'm not gona lie, applying this butyl (in a 90 degree room) was hell! It is much more stringy and hard to work with. I ended up using a bit too much butyl, but it was in the name of being 100% leak proof. I also permanently sealed the top circular cover since it's dang near useless and only opens the door to potential issues.


A nice before / after



Now for installed pics.






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Last edited by Dking078; 1st January 2016 at 10:50 PM.
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post #2 of 18 Old 1st January 2016, 09:37 PM
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post #3 of 18 Old 1st January 2016, 10:22 PM
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Nice Work!!! You should have put some EVOX-Rs or FX-R 1.1's in there while you had it open!
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post #4 of 18 Old 1st January 2016, 10:24 PM Thread Starter
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Quote:
Originally Posted by therealet23 View Post
Nice Work!!! You should have put some EVOX-Rs or FX-R 1.1's in there while you had it open!
Not gona lie, I was very tempted! But since it's a first attempt I played it safe. Maybe if I ever do a V2 set

2003 BMW 540i [Sterling Gray / O5SW M5 Black Interior]
[Msport] [Mods from A-Z] [Two-Tone Interior]
The one true authority of E39 Trim. --E39 Trim Information Thread [Click]

For Sale:

2004 BMW X5 4.8is [Black/Black] [Click]
E39 OEM Refreshed Xenons with new DJ Auto euro lenses! [Click]
E60 Windshield washer sprayer nozzles "Fan" style [Click]
E39 HVAC Buttons [Click]
Got Broken E39 Rear Quarter sun shades? [Click]

Random stuff I don't list on the board: https://www.ebay.com/usr/dking056
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post #5 of 18 Old 2nd January 2016, 05:15 PM
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They look great!

By any chance, did you check to see if the amber reflectors could be used in place of the clear corners on the DJ Auto lenses?

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post #6 of 18 Old 2nd January 2016, 07:10 PM Thread Starter
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Quote:
Originally Posted by Will. View Post
They look great!

By any chance, did you check to see if the amber reflectors could be used in place of the clear corners on the DJ Auto lenses?

Unfortunately, I did not try this.

2003 BMW 540i [Sterling Gray / O5SW M5 Black Interior]
[Msport] [Mods from A-Z] [Two-Tone Interior]
The one true authority of E39 Trim. --E39 Trim Information Thread [Click]

For Sale:

2004 BMW X5 4.8is [Black/Black] [Click]
E39 OEM Refreshed Xenons with new DJ Auto euro lenses! [Click]
E60 Windshield washer sprayer nozzles "Fan" style [Click]
E39 HVAC Buttons [Click]
Got Broken E39 Rear Quarter sun shades? [Click]

Random stuff I don't list on the board: https://www.ebay.com/usr/dking056
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post #7 of 18 Old 3rd January 2016, 12:00 AM
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Good job Daniel.
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post #8 of 18 Old 5th January 2016, 10:01 AM
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Very nice! Where abouts are you located in LA?

I just attempted heating and opening my lamps (2002 M5) only to find 7 mins at 270 deg, and heat guns don't make the glue gooey. I'm guessing these may be the newer unbakable glue? It looks and feels like hard silicone, and doesn't get soft with heat. ( I've opened other lamps before in the past).

That being said, I have these lamps, and new adjusters... And a new set of DJauto clear lenses, just like yours.
Would you possible be able to help me out and install the DJ auto lenses for me ? If possible, how much would you charge?
:-)

Thanks!
-Joe

Last edited by ObjectEdit; 5th January 2016 at 10:02 AM.
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post #9 of 18 Old 5th January 2016, 04:54 PM
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Very nice work! So if those headlamps are almost permanently sealed (because they are off a 2003), I assume it is due to the fact that the sealant they used is not very pliable, and hardens to almost a solid. If this is the case, how were you able to remove the sealant and plastic that remained in the channel after you dremmeled the lenses off?

I hope you retained and reused the vents with the rubber caps in the rear of the housing. They are vital to keeping condensation from occurring inside the assembly.

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post #10 of 18 Old 5th January 2016, 06:24 PM
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Very nice. A cheaper option to the EVO-X is to use an optically clear lens. Makes a significant difference.
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