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.
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.
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
Oem Hella output
Modded EvoX-R output
Orion angel eyes soldered in and Valeo D1S-D2S adapters
Indicator lens, oem
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.
Hard to photograph black headlights, sorry.
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.