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

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



Parts list:
Matsu****a ballasts 35W setup
Morimoto 5000K D2S bulbs
E46 bi-xenon projector housings
ZKW-R clear lenses
H7 wiring harness converted to work with H11 setup

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.

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.

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.

DDM


E46



Will continue to update the thread as the project goes along. More than likely wont finish this weekend as I need some more supplies.

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.



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.

E46


ZKW-R



Stock projector to E46 projector comparison





These are the shields that are required for the color modification. Used a roll of thin aluminum flashing and was cut with scissors.





Final results with E46 projectors, ZKW-R lenses installed, Morimoto 5000K D2S bulbs, AMP adapters to DDM 55W ballasts.
Here are the final results of the retrofit









Modified by ForceFed Motorsports at 5:21 PM 12-1-2009

Modified by ForceFed Motorsports at 5:23 PM 12-1-2009

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


http://www.wolstentech.com/pro...s.php
 

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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


Thats without the shied mod too which makes a huge difference. Example...
 

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Discussion Starter · #8 ·
Re: (kpsingh0)

Quote, originally posted by kpsingh0 »
this whole thread went over my head. whats this do?

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.

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.

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 http://********************/smile/emthup.gif
 

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Discussion Starter · #11 ·
Re: (sanatarium)

Or contact matt @ theretrofitsource.com for all your hid retrofit needs
 

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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 http://********************/smile/emthup.gif

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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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.

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 http://********************/smile/emthup.gif
 

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Discussion Starter · #20 ·
Re: (theshadow27)

Quote, originally posted by theshadow27 »
Optics are a blast. Are the lenses acrylic or glass?

Two peoples opinions say glass haha.

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.

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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Discussion Starter · #21 ·
Re: (AthruC)

Quote, originally posted by AthruC »
I'm not quite sure, but since it's not an issue that can be solved with a simple resistor... or can it?

Shadow figured out the PWM circuit. Problem is the harness that I ordered only uses one input from the head light. The passenger side low beam bulb connector doesnt require being plugged into anything for the lights to function.

I think i need to fake that out with a resistor and then possibly install one of shadows capicitor units as well to clear the BOW message.
 

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Discussion Starter · #23 ·
Re: (sanatarium)

Half way there http://********************/smile/emthup.gif haha
 

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Discussion Starter · #25 ·
Re: (theshadow27)

Everything was purchased thru theretrofitsource.com http://********************/smile/emthup.gif

Pretty sure they produce those lenses. I have the E46 lenses that im replacing i could put in the halogen projectors and using the DDM kit show the difference in projection/cut off line http://********************/smile/emthup.gif

Would be the cheaper alternative for most if they dont wanna go with the full deal.
 

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Discussion Starter · #27 ·
Re:

Not terribly worried about not having auto leveling and the whole works of a factory xenon setup. Way i look at it this is a much more responsible way to do HID's being that by going the extra mile for a nice cut off line your really helping on coming traffic.

Its the haze from cheap HID's and poor projection that blinds on coming traffic. Making the color cool is just a bonus for looks haha.
 

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Discussion Starter · #30 ·
Re: Re: (kpsingh0)

Thanks but im learning here too. Never realized that there was this much involved in projection optics lol. Using two screw clamps for my shield mod, they are precurved nearly perfect, the right thickness, and the perfect height for adjustment.

Im going to cut them at work tomoro and then modify the lense housings to fit the lense further out like the OE ones sit. From there just routing the wiring harness and tweaking with the shields how I like them.
 

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Discussion Starter · #33 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (I Saw 50)

Quote, originally posted by I Saw 50 »
Now what exactly does that line do in the projector lens compared from stock to that super clear one? Is it for the light cutoff, diffuser?

Yes, but if you look at it closely its not straight and is modified to keep the light projected a certain way. Its also attached to a solenoid like a flapper and when your high beams are on pulls back allowing more like to project thru the lense without the filter of the cut off line.

The idea is that by making a bent shield you are projecting the light wider, the acura tls and tsx are like this. Also by adjusting and tweaking the shield back and forth changes the color.

Unfortunately not being an optics professional I cant tell you exactly why, just know the how lol.
 

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Discussion Starter · #35 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (S40Racer)

Yeah it might, if you go to this site you will be able to see the difference between stock projectors and ones that have been upgraded with clear lenses and the shield mod http://********************/smile/emthup.gif

http://www.geocities.com/JVXdr...n.htm
 

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Discussion Starter · #38 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (sanatarium)

I know right, some crazy work. I dont expect mine to look nearly that good but anything close would be amazing. Just waiting on some H11 female connectors right now.

Was trying to get these done this weekend but there was a hang up.
 

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Discussion Starter · #43 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (sanatarium)

Quote, originally posted by sanatarium »
I think I'm going to pick up a set of TSX lenses and build a shield and see what kind of results I can get with the stock projector.

The TSX lenses are 2.5" I believe so you will have to make some sort of holder to center them. They seem to produce the best beam but with the ZKW-R lenses you have the same optimal quality just a larger lense which changes the output if im not mistaken.

At this point I want to mess with the shields on these E46 components and then go from there. Might in the future switch to to FX-R shiz because the lights are teh crazy


Ill probably have time tonight to start tweeking with them again. Have some clamps im testing that I cut because they have a nice curve already. Then going to try some flat ones with so different cuts in them.
 

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Discussion Starter · #46 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (sanatarium)

They are 3" http://********************/smile/emthup.gif Give or take a few thousandths
 

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Discussion Starter · #49 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (theshadow27)

Im not 100% sure, would make sense unfortunately if I had to guess some of the head light designs wouldnt allow a universal projector. I think why the E46's were recommend was purely for the fact that they are exact bolt in for our head lights. Others could be made to fit but having them bolt right up is awesome.

I would also like to have the Bi-xenon feature but if I make the shields curved towards the lenses dont think id be able to get them to work.

Connectors should be here tomoro and then I can go to town on it again
 

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Discussion Starter · #52 ·
Re: D2S HID retrofit, E46 projectors, Matsu**** ... (theshadow27)

Wow hella weak sauce, all that guys work just gone over night lol. Glad you grabbed the info http://********************/smile/emthup.gif
 
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