DIY-Bi-Xenon headlight conversion - Really can be done- $300
07-05-2011, 10:58 AM
#1
Instructor
Thread Starter
DIY-Bi-Xenon headlight conversion - Really can be done- $300
Just wanted to share my newest project. Converting my headlights to Bi-Xenon lights. Pics can't do the look justice. Really improved my night driving vision and gave the headlights a modern look. Well worth the price & effort.
EDIT:
Here are my instructions. I'll post pics later tonight.
1. Use tool (5mm) to remove headlight assemblies from fenders
2. Remove screws and signal triangle Remove all bulbs, tape openings closed
3. Use heat gun to soften sealant and separate lens from assembly
a. Start from top of lens using screwdriver or wide blade tool
b. Use wedges to keep gap open
c. Do melt plastic with too much heat- monitor heat with digital thermometer
d. Wear gloves & old clothes– everything with get black sealant on it
4. Remove 2 screws and slide out clear bezel
5. Remove inside screws and remove reflector
6. Use file to open socket opening so you can fit in new Xenon reflector housing
7. Use grinder to remove the tab in reflector
8. Install Xenon reflector assemble into Porsche reflector, and tighten
9. Reassemble the reflector and bezel back into the light housing
a. Be careful not to over tighten screws
b. Make sure everything is back in place
10. Insert Xenon bulb into Xenon reflector ( after cleaning bulb)
11. Attach wiring
12. Slide headlight assembly back in to fender so you can rotate the reflector so that the beam is perfectly horizontal. You will set height later on.
13. Remove headlight assemblies, disconnect wiring
14. Reaffix the lens to the headlight assembly with sealant (I used urethane windshield adhesive, but there is headlight lens sealant available)
15. Reconnect wiring and connect high beam connections.
16. Pack wiring and ballasts into the headlight assembly, install rear covers
17. Install headlight assemblies back into the fenders
18. Confirm that they work.
19. Use hex tool to align height of low beams
EDIT:
Here are my instructions. I'll post pics later tonight.
1. Use tool (5mm) to remove headlight assemblies from fenders
2. Remove screws and signal triangle Remove all bulbs, tape openings closed
3. Use heat gun to soften sealant and separate lens from assembly
a. Start from top of lens using screwdriver or wide blade tool
b. Use wedges to keep gap open
c. Do melt plastic with too much heat- monitor heat with digital thermometer
d. Wear gloves & old clothes– everything with get black sealant on it
4. Remove 2 screws and slide out clear bezel
5. Remove inside screws and remove reflector
6. Use file to open socket opening so you can fit in new Xenon reflector housing
7. Use grinder to remove the tab in reflector
8. Install Xenon reflector assemble into Porsche reflector, and tighten
9. Reassemble the reflector and bezel back into the light housing
a. Be careful not to over tighten screws
b. Make sure everything is back in place
10. Insert Xenon bulb into Xenon reflector ( after cleaning bulb)
11. Attach wiring
12. Slide headlight assembly back in to fender so you can rotate the reflector so that the beam is perfectly horizontal. You will set height later on.
13. Remove headlight assemblies, disconnect wiring
14. Reaffix the lens to the headlight assembly with sealant (I used urethane windshield adhesive, but there is headlight lens sealant available)
15. Reconnect wiring and connect high beam connections.
16. Pack wiring and ballasts into the headlight assembly, install rear covers
17. Install headlight assemblies back into the fenders
18. Confirm that they work.
19. Use hex tool to align height of low beams
Last edited by 15psi; 07-20-2011 at 03:33 PM.
07-05-2011, 12:49 PM
#3
Instructor
Thread Starter
Yes, I'll include all the gory details & pics later, but I left camera at home, but I snapped this pic with new EVO 3D as I left the house.
Removing the cover lens is real fun! Luckily I had an extra headlight to practice on before I tackled the ones from my car.
You have to completely disassemble the headlights in order to install the lights. BUT the difference in illumination is fantastic. Plus a more modern look at 1/10th the cost of Litronics AND the highbeams are Xenon, Litronics aren't.
Removing the cover lens is real fun! Luckily I had an extra headlight to practice on before I tackled the ones from my car.
You have to completely disassemble the headlights in order to install the lights. BUT the difference in illumination is fantastic. Plus a more modern look at 1/10th the cost of Litronics AND the highbeams are Xenon, Litronics aren't.
Last edited by 15psi; 07-05-2011 at 01:07 PM.
07-06-2011, 11:40 AM
#6
Instructor
Thread Starter
Lots of progress last night, but ran out of time before completion.
Here is a pic while I was checking the alignment, the pic of the front of the car doesn't capture the look of the lights accurately, I'll retake it with different exposure so you can see the Xenon lenses as they actually look.
Also included a pic of the Bi-Xenon parts that I bought. I'll start to organize pics and instructions.
What a great improvement in LIGHTING!!!! And gave the car's lights a more modern look even when they are off.
Here is a pic while I was checking the alignment, the pic of the front of the car doesn't capture the look of the lights accurately, I'll retake it with different exposure so you can see the Xenon lenses as they actually look.
Also included a pic of the Bi-Xenon parts that I bought. I'll start to organize pics and instructions.
What a great improvement in LIGHTING!!!! And gave the car's lights a more modern look even when they are off.
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07-06-2011, 02:15 PM
#8
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Looks great! I'll be following this one for sure.
Did you have an amber turn signal section in your covers and amber triangles along the bottom to start with or are you somehow changing them to clear in addition to the Xenon? I had always thought we were stuck with the amber bottom section since its a one piece lense cover.
Did you have an amber turn signal section in your covers and amber triangles along the bottom to start with or are you somehow changing them to clear in addition to the Xenon? I had always thought we were stuck with the amber bottom section since its a one piece lense cover.
07-06-2011, 07:46 PM
#11
If you buy the Bosch parts, it's an easy job to do. Even wiring in the leveling controller is simple and takes less time that one might think.
Did the conversion on a customers car, lights, controller and install was less than $3k.
Did the conversion on a customers car, lights, controller and install was less than $3k.
07-07-2011, 11:06 AM
#12
Instructor
Thread Starter
[QUOTE=SeanR;8692132]If you buy the Bosch parts, it's an easy job to do. Even wiring in the leveling controller is simple and takes less time that one might think.
Did the conversion on a customers car, lights, controller and install was less than $3k.
QUOTE]
Hmmmm $3,000 vs <$300. Oh yeah, the Litronic is not Bi-Xenon. The early Litronic used Halogen brights. This wiring uses the H1 light socket that plugged into your Halogen bulb.
Did the conversion on a customers car, lights, controller and install was less than $3k.
QUOTE]
Hmmmm $3,000 vs <$300. Oh yeah, the Litronic is not Bi-Xenon. The early Litronic used Halogen brights. This wiring uses the H1 light socket that plugged into your Halogen bulb.
Last edited by 15psi; 07-07-2011 at 01:11 PM.
