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Discussion Starter · #1 · (Edited)
D2S HID retrofit, E46 projectors, Matsu****a Ballasts, Morimoto 5000K, 35W

<p>Beginning my HID retrofit today. Going to take more time than I thought as there is a lot more involved with tuning the HID output than expected. All parts ordered thru my friends at TheRetrofitSource.com<p><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0702.jpg" BORDER="0"><p>Parts list:<br>Matsu****a ballasts 35W setup<br>Morimoto 5000K D2S bulbs <br>E46 bi-xenon projector housings<br>ZKW-R clear lenses <br>H7 wiring harness converted to work with H11 setup <p>The wiring harness only uses one of the low beam bulb inputs and then using a relay system attached to the battery runs an extension harness over to the passenger side ballast. An H11 harness kit wasnt available so a H11 female connector just needs to be swapped out for the H7 that comes with it.<p>So far that ive seen today is due to only using one head light low beam connector connected to the harness theres a bulb out message. Have to figure out how to fake out the passenger side harness.<p>With nothing installed into the head lights yet I took some comparison pics just to show the difference between a 55W DDM kit with 45000K bulbs and the 35W retrofit with E46 projectors and the factory lenses that came with them.<p>DDM<br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0700.jpg" BORDER="0"><p>E46<br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0695.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0696.jpg" BORDER="0"><p>Will continue to update the thread as the project goes along. More than likely wont finish this weekend as I need some more supplies.<p>By adjusting the cut off shield or the "shield mod" as they call it you can alter the cut off line color and clarity. Ill be using a roll of flashing to adjust and alter the output to my liking and then drill out the rivets that hold the RV shield on to mount it.<p><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0706.jpg" BORDER="0"><p>I also have clear ZKW-R lenses to swap in which changes the clarity and output of the bulbs quite a bit. Did the one side but need to change how it mounts inside the projector a bit more. You can see the difference from the E46 lenses compared to the clears quite a bit just visibly.<p>E46<br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0704.jpg" BORDER="0"><p>ZKW-R<br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0705.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0707.jpg" BORDER="0"><p>Stock projector to E46 projector comparison<br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0715.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0716.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0717.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0719.jpg" BORDER="0"><p>These are the shields that are required for the color modification. Used a roll of thin aluminum flashing and was cut with scissors.<p><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0747.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0748.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0749.jpg" BORDER="0"><p>Final results with E46 projectors, ZKW-R lenses installed, Morimoto 5000K D2S bulbs, AMP adapters to DDM 55W ballasts.<br>Here are the final results of the retrofit <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/biggrin.gif" BORDER="0"> <br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0810.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0811.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0812.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0814.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0815.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0816.jpg" BORDER="0"><br><IMG SRC="https://www.theeshadow.com/files/volvo/forcefed/DSCN0813.jpg" BORDER="0"><p><i>Modified by ForceFed Motorsports at 5:21 PM 12-1-2009</i><BR><BR>
<i>Modified by ForceFed Motorsports at 5:23 PM 12-1-2009</i>

Should also note that if anyone is experiencing issues with aftermarket ballast firing issues, or just plain worried about the wiper module failure, I used https://www.skbowe.com/ harness to eliminate the original issues I was having with DDM.
 

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Discussion Starter · #2 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (ForceFed Motorsports)

Oh yeah, I bought Bixenon projector housings so if i can get the solenoids to function with the high beam switch Ill have xenon high beams as well <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/biggrin.gif" BORDER="0"> <p><A HREF="http://www.wolstentech.com/products/bixenon/instructions.php" TARGET="_blank">http://www.wolstentech.com/pro...s.php</A>
 

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Re: D2S HID retrofit, E46 projectors, Matsu**** ... (ForceFed Motorsports)

Awesome project Kyle, anxiously awaiting the results, cut off is night and day compared to the DDMs! <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0">
 

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Discussion Starter · #4 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (Bigblk4)

Funny thing is E46 projectors are considered one of the lowest of the quality retrofits too haha. Some of the pics ive seen of other retrofits are crazy. However they are direct bolt in for our bosch headlights <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0"> <p>Thats without the shied mod too which makes a huge difference. Example...<br><IMG SRC="http://www.geocities.jp/retrofitaddict/DSC00745.JPG" BORDER="0">
 

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Re: D2S HID retrofit, E46 projectors, Matsu**** ... (ForceFed Motorsports)

Great Kyle, you just made my DDM kit cry and it now has an inferiority complex... <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0"> Looking good so far!
 

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Discussion Starter · #8 ·
Re: (kpsingh0)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>kpsingh0</b> »</i></TD></TR><TR><TD CLASS="quote">this whole thread went over my head. whats this do?</TD></TR></TABLE><p>Well for starters our cars that are factory halogens are not designed for xenon light. If you look at your lenses they are dimpled, which isnt optimal for xenons.<p>What im doing is converting to D2S bulbs which is a standard OEM bulb by changing the projector housings. Also by replacing the lenses with the clear ZKW-R's they will be the clearest and best projection available.<p>Changing the cut off shield (the metal flap in front of the bulb) changes how much fuzz so to speak is above the cut off line and how sharp it is. Also the "hue" that you see on luxory and exotic cars can be mimic'd by fine tuning the shield <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0">
 

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Discussion Starter · #11 ·
Re: (sanatarium)

Or contact matt @ theretrofitsource.com for all your hid retrofit needs <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/wink.gif" BORDER="0">
 

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Re: (ForceFed Motorsports)

Oooh, Might do that instead. Thought on DDM HIDs with better projector housings? Or is it necessary to go with all new bulbs and ballasts?
 

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Discussion Starter · #13 ·
Re: (sanatarium)

Hmmm. Well maybe ill throw one of the clear lenses in the stock projectors for you when i remove them and show what the difference will be from stock with the DDM kit <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> <p>That was my initial thought but convinced myself to go 35W so decided to go for the full retrofit. Especially since the bi-xenon projectors are complete bolt on makes things very easy.
 

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Re: (ForceFed Motorsports)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>ForceFed Motorsports</b> »</i></TD></TR><TR><TD CLASS="quote">Hmmm. Well maybe ill throw one of the clear lenses in the stock projectors for you when i remove them and show what the difference will be from stock with the DDM kit <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> </TD></TR></TABLE><p>Are they the same size? I think this would be crucial - there's very little difference between a dichromatic projector and a halogen projector other than the lens and the cutoff. <p>If you need help with the BOW shoot me a note.
 

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Discussion Starter · #16 ·
Re: (theshadow27)

Yeah i believe they are. They are 3" lenses. Only issue is the ZKW-R is just a fudge larger and requires a very small modification to the projector housing, theres a small notch that centers the factory lense. All you need to do is notch the aftermarket lense in order to fit properly... I think lol.<p>As for the BOW I wanna get the retrofit done and complete installed in the car and then figure out the odds and ends. Right now im just workin on getting the cut off line how I like it before I remove the insides of my stock head lights. Kinda fun messin with this stuff though <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0">
 

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Re: (ForceFed Motorsports)

Optics are a blast. Are the lenses acrylic or glass?
 

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Re: (ForceFed Motorsports)

I skimmed over most everything, so sorry if I missed a bit of info.<p>First off, it's awesome that you're doing this retro - kudos. I have something slightly more 'involved' that I've been messing with on/off for the "R" but still have nothing (years later...).<p>That being said, I know that you can take just the projector assembly out of the S40 housing from behind w/ 3-4 screws. If you can get the E46 projo (or another bi-xenon assembly) to line up, or drill holes in the 'mounting surface, or make an adapter plate to mate them, it should be a simple task, no? Just throw them in and call it a day! Of course, if everything in life were that easy... but seriously, Valeo makes the S40 lamps, no? What about a set of Valeo projectors?<p>Also, at least on the set that I have, the 'high' function does work with just a simple +12V - apply voltage and the plunger pushes the cutoff screen out of the way.<p>Seriously though, there should be a projector out there that should nearly fit to just 'screw it in' with. Grrr, crap, I no longer have the internals from my S40 headlamp dissection <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/frown.gif" BORDER="0">
 

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Re: (AthruC)

Okay, I see that you said they are direct 'bolt in' projectors - really you're just trying to be extra fancy with the pretty colors on the cutoff pattern <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/tongue.gif" BORDER="0"><p>The 'bulb out' message you get comes with the territory. The halogens are actually run with a PWM circuit - the bulbs are 'pulsed' very quickly, which has no noticeable effect on the halogens that have a 'slow' burn. Hook up an LED or HID or any other nearly instant-on lighting source and you get a strobe light effect. Whether it's also a resistance issue, or whether the computer is measuring the cycle at which it receives, I'm not quite sure, but since it's not an issue that can be solved with a simple resistor... or can it?<p>I think I just confused myself.
 

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Discussion Starter · #20 ·
Re: (theshadow27)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>theshadow27</b> »</i></TD></TR><TR><TD CLASS="quote">Optics are a blast. Are the lenses acrylic or glass?</TD></TR></TABLE><p>Two peoples opinions say glass haha.<p>I know there are valeo projectors out there that are awesome quality. After talking to matt these are the projectors that he recommended since they are direct bolt in. Comparing to the S40 internals they look spot on the same which will make the install easy. <p>Going to grab some materials tomoro I think to start messing with the cut off line. Was going to go grab some stuff from the hardware store but have a ton of t bolt clamps which is the curve that im looking for so might cut a few up and try that.
 
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