BMW E60 Halogen Headlight Restoration and Retrofit - BMW M5 Forum and M6 Forums
E60 M5 and E61 M5 Touring Discussion 2005- Advertiser's Forum

 10Likes
  • 7 Post By ucsbwsr
  • 3 Post By ucsbwsr
 
LinkBack Thread Tools Rate Thread
Old 3rd March 2016, 06:21 PM Thread Starter
ucsbwsr
Member, P400 Sport, DSC On (>550)
 
ucsbwsr's Avatar
 
Join Date: Jul 2008
Location: San Diego
Posts: 560
Thanks: 9
Thanked 68 Times in 47 Posts
Garage
BMW E60 Halogen Headlight Restoration and Retrofit

I snagged a pair of BMW E60 halogen headlights off eBay and they have sat in my garage for over a year and I finally got around to them. This was another experimental/practice build.

Although the M5 never had halogen headlights this may be helpful for those with pre-LCI headlights and are interested to see what some options are in terms of aesthetics, these headlights are essentially the same minus the factory Bi-Xenon projector and AFS motors. If nothing else, transformations like this are always fun to observe.

Before


After


First things first, lens restoration, my wagon was kind enough to donate it's headlight brackets for the process


Before:





800


1,200 pics skipped, 1,500grit


2,000g pics skipped, 3,000g


Plastic-x


Finishing Compound, Opti-Lens was applied after this.


After



I thought about it, I wanted to... but not this time, the LS430 projector will continue to wait for the correct housing.


This was the worst permaseal I have encountered. I was actually pleasantly surprised that the E60 housing could be opened, not sure if they used a different permaseal on the older housings or if the age of the headlight had anything to do with it. Either way this sucked, even with those goofy "headlight sealant removal tools"


This corner was a nightmare in particular, you can imagine...BMW permaseal at those angles.


The bowl was nice and tall but just not deep enough. I wasn't confident enough to start hacking up the LS430 shroud with the possibility of it not fitting so I aborted mission.


I was thinking of running the RX AFS but again the real clearance was going to be an issue and I wasn't willing to compromise the housings caps/seal on this build so I went with the very boring but very functional MH1 7.0. With an E46 shroud I has the idea of keeping this an oem+ build with chrome shrouds and everything buuuuuuuuuuuuuuuuttt why oem+ when I can experiment with something more exciting


I am so predictable: black demon eye and black bowls


Shrouds rings mounted and shrouds painted


Rotation done and locked in


Now for aesthetics, the oem reflector and turn signal lens are a pretty crude design


Omitting them wasn't really an option as they would leave an obvious void


My hopes were to blend the lens in with the reflector so I tried some silver/aluminum paint and frosted the lens


The chrome was still underneath


Frosted the angel eyes as well



I painted the underlying chrome silver to see if that would help visually join the 2 pieces, noooooot really



Blacked out the ring carriers


The silver reflector wasn't working so the next plan was to black it out, to tone down the frosted lens I painted the turn signal bowl black, frosted rings live on.




Mounted the ballast internally with some VHB tape


With the main headlight trim in place it is a tight fit but it works


Everything is internal


Blacked out angel eyes



Bulbs were in rough shape


I had some LED bulbs lying around


All sealed up


Nighttime running lights


Turn signal performs well with the frosted lens


HID


Some demo shots on my wagon, sorry for the pics, it was hard to capture the headlights without a reflection






Output shots: 35w DDM ballast and 5.5k DDM bulbs. Output is great IMO. I was experiencing some slight bowing on the cutoff, not sure if other MH1 7.0 owners are experiencing this or if I should chalk it up to DDM bulb fitment (hotspots and beam pattern are great).








2008 N54-Powered E61 M5 Wagon: ~600whp ~600wtq
- AWD-RWD Conversion, OEM M5 Drivetrain Retrofit, Manual Trans Swap, Spec 3+ Clutch, MFactory SMFW
- OEM M5 Brakes, KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC 19x9.5 19x11, Hankook V12
- Hexon RR550 Hybrid Turbos, Custom Turbo Inlets, AR DP, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC,
- BMS JB4, E85 Flash, Fuel-It Stage 2 LPFP, EOS Port Injection Manifold, Custom 3" Exhaust
- OEM M5 Front Bumper, OEM M5 Front Fenders (Vents Deleted), OEM M5 Skirts, OEM M5 Mirrors, M-Tech Rep Rear Bumper
- Quad Projector Headlights, Custom Tail Lights, Rigid SR 6" Reverse Light, Full LED Interior/Exterior Lighting
ucsbwsr is offline  
The Following 2 Users Say Thank You to ucsbwsr For This Useful Post:
FastHackem (3rd March 2016)
Sponsored Links
Advertisement
 
Old 3rd March 2016, 06:44 PM
LeeDan00
m5board.comoholic (>1000 posts)
 
LeeDan00's Avatar
 
Join Date: Jan 2011
Location: Bay Area, CA
Posts: 1,828
Thanks: 31
Thanked 77 Times in 76 Posts
amazing work as usual bud! cutoff and light output is amazing for what these MH1's are. can't wait for you to start my build and other than aesthetics, I'm really looking for lighting performance over the stock lights. good work my man.


Dan

2007 ESS SC'd 6MT
ESS VT2-650 Supercharger with Intercooler
ESS Alpha N Tune
Vortech BOV vta to replace the stock recirculating one (OMG loud!)
Rod bearings changed 8/10/15 at 88k miles
Dinan sections 1 - 3. Straight pipe 4'' "loudest" version Dinan offers. (Sounds amazing at WOT)
Secondary cats and resonator removed
KWv3
Flat bottom steering wheel all leather with M stitching
RPi SV1 Oil Cooler in silver
RD Sway Bars
Brembo BBK 405/380mm in factory yellow
Dinan Monoballs
Hardwired V1
CF hood by Seibon. E9x style with hood bump and functional vents
CF Hamann front lip
CF rear diffuser
CF trunk lid from member Socale39
ZHP shift knob
BBS fi-r with Michelin Cup2's
Custom built headlights by Evan with fx-r projectors and Orion v2's and full blackout
Gloss black kidneys and side vents
Gloss black M5 badge
Gloss black ESS badge
LCI tails with special brake effect done by Simon aka BCD
LED front, side, and license plate
Dyno'd 598wrhp and 413tq on Dynojet 10/29/15 on stock headers




2010 Dinan S3 5.7L complete catalog car serial numbered 6MT
LeeDan00 is offline  
Old 3rd March 2016, 07:48 PM
FastHackem
Fellow Member (>400)
 
FastHackem's Avatar
 
Join Date: Mar 2014
Location: RICHMOND, TX
Posts: 410
Thanks: 39
Thanked 49 Times in 38 Posts
This is awesome, Evan! May I request some more info the next time around on the beam horizontal alignment and fixing the projector units to the bowls? I found this part the most time consuming and stressful when putting projectors in the WRX. Passenger side beam came slightly misaligned after tightening the nut on the back. I knew I should have fired them up one more time before sealing, SMH.

The Mind Is a Terrible Thing
2006 M5 (Garage Queen)
2007 Santa Fe (Wife's DD)
2005 WRX (My DD)
1983 944 (Garage King & First Ride)
FastHackem is offline  
 
Old 3rd March 2016, 08:54 PM
DocsV10
Member, P500, DSC On (>600)
 
DocsV10's Avatar
 
Join Date: Dec 2013
Location: DFW (Texas)
Posts: 690
Thanks: 19
Thanked 45 Times in 33 Posts
Wink

Great post! Thanks for sharing your write up!

Question: I've always hated the orange side reflectors on my pre-LCI headlights. Currently, I have some 3M carbon fiber wrap covering them, and honestly, it doesn't look that bad. However, I'd like to paint them eventually. What type of paint would you recommend? I'll most likely mask off the area and paint the headlights without removing them.

Thanks!
Attached Thumbnails
Click image for larger version

Name:	IMG_3925.JPG
Views:	1940
Size:	2.62 MB
ID:	679978   Click image for larger version

Name:	IMG_5335.JPG
Views:	6350
Size:	2.66 MB
ID:	679986   Click image for larger version

Name:	IMG_5339.JPG
Views:	1296
Size:	1.91 MB
ID:	679994   Click image for larger version

Name:	IMG_5372.JPG
Views:	1859
Size:	1.45 MB
ID:	680002  

2006 INTERLAGOS BLUE E60 ///M5
///PERFORMANCE
*Evolve Stage 3 Tune
*Evolve/Supersprint Long Tube Headers (Ceramic Coated by Swain Tech)

*Primary + Secondary Cat Delete
*Supersprint Section 1 (Cat-Delete 70mm Test Pipes)
*Supersprint Section 2 (Resonated 70mm X-Pipe)
*Eisenmann Race Section 3 (83mm Round Tips; Powdercoated Wet Black)
*Agency Power Pulley
*AFE Pro Dry-S Drop-in Air Filters
*AFE Ram-Air Intake Scoops
*Charcoal Filter Delete
*Sprint Throttle Booster V2


///EXTERIOR
*WeissLicht Angel Eyes/Halos (White)
*WeissLicht LED Front Turn Signal Bulbs (White)
*WeissLicht LED License Plate Bulbs (White)
*WeissLicht LED Rear Turn Signal Bulbs (Amber)
*
WeissLicht LED Reverse Bulbs (6000K)
*F10-Style LED Sidemarkers (White)

*AutoCarbon CF Kidney Grille
*AutoCarbon CF Side Grilles
*AutoCarbon CF Mirror Covers
*CF Rear Spoiler Inlay
*CF Hamann Front Splitter
*Powdercoated OEM 19s (Kingsport Metallic Gray)

///SUSPENSION
*H&R Sport Springs
*H&R 12mm Spacers

///INTERIOR
*Interior LED Kit (White)
*M-Tech Brushed Aluminum Sport Pedals
*M5 Floor Mats

///OTHER
*Euro SMG 3 Flash
*Euro MDM Flash
*Custom Coding (by NTX Coding)

*Custom CF Hydro-Dipped Engine Bay Parts
*Cold-Start Delete
DocsV10 is offline  
Old 3rd March 2016, 11:33 PM Thread Starter
ucsbwsr
Member, P400 Sport, DSC On (>550)
 
ucsbwsr's Avatar
 
Join Date: Jul 2008
Location: San Diego
Posts: 560
Thanks: 9
Thanked 68 Times in 47 Posts
Garage
Quote:
Originally Posted by FastHackem View Post
This is awesome, Evan! May I request some more info the next time around on the beam horizontal alignment and fixing the projector units to the bowls? I found this part the most time consuming and stressful when putting projectors in the WRX. Passenger side beam came slightly misaligned after tightening the nut on the back. I knew I should have fired them up one more time before sealing, SMH.
Projector aligning can be challenging if you don't have the car in your presence, especially if you are adding a projector to a halogen bowl (as opposed to replacing a projector), the only way to know for sure is to confirm and finalize rotation while the headlights are properly mounted on the car.

If you are replacing a projector then make sure to mark the cutoffs and align the replacement projector to the original markings. Unfortunately I don't have any universal tricks for mounting and aligning a projector in a halogen housing if you only have the headlights to work with. It is possible with some headlights but usually hard to replicate exactly how they would sit on the vehicle.


Quote:
Originally Posted by DocsV10 View Post
Great post! Thanks for sharing your write up!

Question: I've always hated the orange side reflectors on my pre-LCI headlights. Currently, I have some 3M carbon fiber wrap covering them, and honestly, it doesn't look that bad. However, I'd like to paint them eventually. What type of paint would you recommend? I'll most likely mask off the area and paint the headlights without removing them.

Thanks!
For what they are and how much it costs, those vinyl decals are pretty effective, I have seen the ones which are designed off the oem Euro reflectors and unless you within 25ft, it is hard to tell.

Of course opening the headlights and physically changing the reflector is ideal. I typically use a high temp paint on most of my headlight builds, Rustoleum High Temp was used on this build. You can paint the reflector with any paint you like, just make sure the reflector is prepped.

What I think would look the best and maintain 100% functionality is a clear reflector. On this build I would have frosted it to match the signal lens but I love the look of most clear reflectors. Since painting the reflector inevitably kills the reflective capabilities I purchased some reflective finish I was going to test out on the silver reflectors but the build dictated those were going to be black so I never got around to it.

Also, the reflector and signal lens are joined to the headlight lens, so once the lens is cut off you will pop them from there.

Evan

2008 N54-Powered E61 M5 Wagon: ~600whp ~600wtq
- AWD-RWD Conversion, OEM M5 Drivetrain Retrofit, Manual Trans Swap, Spec 3+ Clutch, MFactory SMFW
- OEM M5 Brakes, KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC 19x9.5 19x11, Hankook V12
- Hexon RR550 Hybrid Turbos, Custom Turbo Inlets, AR DP, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC,
- BMS JB4, E85 Flash, Fuel-It Stage 2 LPFP, EOS Port Injection Manifold, Custom 3" Exhaust
- OEM M5 Front Bumper, OEM M5 Front Fenders (Vents Deleted), OEM M5 Skirts, OEM M5 Mirrors, M-Tech Rep Rear Bumper
- Quad Projector Headlights, Custom Tail Lights, Rigid SR 6" Reverse Light, Full LED Interior/Exterior Lighting
ucsbwsr is offline  
Old 4th March 2016, 09:57 PM
m5 guy
Member, Sport: On DSC: Off
 
m5 guy's Avatar
 
Join Date: May 2012
Location: Hawaii
Posts: 245
Thanks: 25
Thanked 11 Times in 10 Posts
Garage


So sick. Headlight pron here. Keep it up! I'm liking that frost idea. Does that affect light output at all?


2016 F10 M5 Space Gray-Black
2010 E60 M5 Saphire Black-Black SOLD
2012 E70 X5M Monte Carlo Blue-Silverstone SOLD
2001 E46 M3 Oxford Green Metallic II-Cinnamon SOLD
m5 guy is offline  
Old 4th March 2016, 10:34 PM Thread Starter
ucsbwsr
Member, P400 Sport, DSC On (>550)
 
ucsbwsr's Avatar
 
Join Date: Jul 2008
Location: San Diego
Posts: 560
Thanks: 9
Thanked 68 Times in 47 Posts
Garage
Quote:
Originally Posted by m5 guy View Post


So sick. Headlight pron here. Keep it up! I'm liking that frost idea. Does that affect light output at all?
Thank you, I am a huge fan of frosting the clear plastics, gives it a unique look but also retains function. The frosting changes the optics a bit but that depends on what it is applied to. For example, on my tail lights with the LED running light tubes, after frosting them the tubes were more intense near the diode but weaker further away since the frosting scavengers/diffuses more light than the unmodified tubes which originally were a gloss finish with ribs to diffuse the light.

So on this particular reflector I would say functionally it is a wash, the turn signal light is maybe not projected as far as it otherwise would be but the light that is diffused from the frosting is still functional for grabbing the attention of surrounding traffic.

Evan

Last edited by ucsbwsr; 4th March 2016 at 10:35 PM.
ucsbwsr is offline  
Old 15th March 2016, 06:41 AM
M6 Beast
Member, Sport: Off DSC: On (>50 posts)
 
M6 Beast's Avatar
 
Join Date: Jul 2011
Location: Pleasanton, CA
Posts: 80
Thanks: 6
Thanked 3 Times in 3 Posts
M6 Beast is offline  
 

Bookmarks

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the BMW M5 Forum and M6 Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Thread Tools
Rate This Thread
Rate This Thread:



Similar Threads
Thread Thread Starter Forum Replies Last Post
Headlight Restoration hcaleman E39 M5 and E52 Z8 Discussion 13 2nd January 2016 10:38 PM
Headlight restoration Steveb34 E60 M5 and E61 M5 Touring Discussion 17 25th February 2013 06:12 PM
Headlight restoration Stunin5 E60 M5 and E61 M5 Touring Discussion 9 13th November 2012 12:17 AM
3M Headlight Restoration Results. nanda007 E39 M5 and E52 Z8 Discussion 20 13th July 2011 09:37 PM
halogen headlight to oem xenon? edya E39 M5 and E52 Z8 Discussion 6 26th December 2008 11:09 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome