Dan's Custom Headlights - BMW M5 Forum and M6 Forums
E60 M5 and E61 M5 Touring Discussion 2005- Advertiser's Forum

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post #1 of 20 Old 30th May 2016, 11:37 PM Thread Starter
ucsbwsr
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Dan's Custom Headlights

I built a set of high performance headlights for Dan and I thought I would share the process.

Unfortunately, these headlights are an absolute nightmare to work on and I do not plan on building any E6X headlights in the future, I will be focusing my efforts elsewhere. If your second car happens to be a Tesla Model S then you are in luck!

The pre LCI HID has a unique design for the AFS cradle and the way it mounts to the oem Hella projector on top with a pivot point. Most other AFS systems (E6X LCI HID included) have a more conventional setup where the projector simply bolts to a cradle using the mounting points at the 4 corners. This design really limited projector options and the best solution was the Morimoto EvoX-R, which is a reverse-engineered unit based off of the another Hella projector. There are projectors with wider output but the EvoX-R has great intensity and also a top-notch high beam.

Build Specs
Morimoto EvoX-R Bi-Xenon projectors (modified)
Morimoto xb D2S bulbs
Orion V2 Opaque
OEM Hella Ballasts
Valeo D1S-D2S Ignitor/Adapters
Black Housing Paint
Red Projector Demon Eye (Passive)
Frosted Turn Signal Lens
DRL/High Beam Assist Delete

Here are some pictures of notes from the build, I am sure Dan will share some photos once they are installed on his car.

Evan


Open sesame


Oem projector mounted in the overly-complicated AFS cradle.




Notice the circular hole in the projector, this is the pivot point.


That hole is a Hella-specific design and these other projectors (Morimoto MH1 7.0 and Lexus RX350 Bi-X) don't have such a mounting point.


A close up of the internal shield on the EvoX-R projector, notice the circled areas. Since those points protrude above the shield they block some light and create dips in the light output, no bueno.


The shield was trimmed to make a recess for the shield stopper to rest in, the other excessive material was cut with a dremel.


After some paint




The top of the shield was sanded down to level out any imperfections from the painting process.


Oem Hella vs Modded EvoX-R


Red Demon eye effect


Modded EvoX-R


Oem Hella output


Modded EvoX-R output


EvoX-R mounted


Orion angel eyes soldered in and Valeo D1S-D2S adapters


Indicator lens, oem


After frost


The Umnitza Orions take a bit or work to get them to seat/fit properly, I expect better fitment considering they are model and year specific. Notice the notch in the middle.


Now it sits flush


Drilled some holes to run the wires out of sight


Angel eye mounted with thin steel wire and some JB Kwik epoxy for security. The wires are noticeable (barely) but offer much better security than other adhesives.


All mounted


Testing


HID


Lens mounted


More testing


Hard to photograph black headlights, sorry.


Before


After

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

Last edited by ucsbwsr; 31st May 2016 at 05:40 PM.
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post #2 of 20 Old 30th May 2016, 11:59 PM
TheShafro
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They look great! How did you "frost" parts?

-Shady H.
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Last edited by TheShafro; 30th May 2016 at 11:59 PM.
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post #3 of 20 Old 31st May 2016, 05:51 AM
m5 guy
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You are insane, those look so awesome and I bet they perform even better. Great job!


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post #4 of 20 Old 31st May 2016, 02:22 PM
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Quote:
Originally Posted by TheShafro View Post
They look great! How did you "frost" parts?
you can buy etching solution from crafts stores that etch(frost) plastic, glass etc.

- Justin

/// 2008 Space Grey M5 (SMG)
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post #5 of 20 Old 31st May 2016, 03:29 PM
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post #7 of 20 Old 31st May 2016, 05:14 PM Thread Starter
ucsbwsr
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Quote:
Originally Posted by TheShafro View Post
They look great! How did you "frost" parts?
Light sanding and a frosting spray paint.
Quote:
Originally Posted by m5 guy View Post
You are insane, those look so awesome and I bet they perform even better. Great job!
Thank you. My focus on every build is high performance light output, aesthetics are secondary ...(but obviously I still care about them).
Quote:
Originally Posted by JGINWS View Post
WOW those look great! Hate that you don't want to do another set ......
If the price is right I may take on a few more builds but considering how difficult these E6X headlights are to open and reseal and the amount of time involved in building them with a full spec of components, I am not many people will be willing to shell out the dough for the mods...
Quote:
Originally Posted by [email protected] View Post
very cool. great work sir
Thank you.

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
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post #8 of 20 Old 31st May 2016, 06:15 PM
uc
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Very Nice!



Rob

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post #9 of 20 Old 31st May 2016, 10:46 PM
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Impressive. Good job!


2008 BMW M5
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post #10 of 20 Old 2nd June 2016, 09:32 PM
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Update: lights were installed yesterday and basically a plug and play setup. to say the least, they're amazing and night and day difference compared to stock lights. I thought stock lights were great, but like comparing TV's, when they're side by side in comparison, you can totally tell the difference. I'll create a new thread when I have time to show the light output and performance. I've finally achieved my want of creating a performance light for my e60 m5. Night driving will be so much more enjoyable with these bad boys.


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
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