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Discussion Starter · #1 · (Edited)
SwedeSpeed P1 (C30, S40, V50, C70) HID Retrofit Index
  1. SKBOWE Plug-and-Play harness for P1 HID conversion (you are here)
  2. Background info, general questions, and share your HID setup <- Non-SKBOWE HID install issues/discussion/WMM kills
  3. KBOWE How-To (Original 2009 Version) build your own PWM filter <- if you want to build your own
  4. Original 2009 investigation and technical discussion on S40 HID issues <- Technical/Engineering discussion on the CEM, PWM, WMM, and alternate designs
  5. ForceFed's E46 D2S Bi-Xenon Projector Retrofit guide
  6. Rewire OEM Bi-Xenon headlights to work on the halogen harness
  7. DRL Disable Alone not enough for safe Aftermarket HID retrofits
  8. LizardOfBodom's EU/RHD Bosch ("E46") Bi-Xenon replica retrofitting writeup + angle eyes + running lights

This thread is for discussion of the SKBOWE PWM filter, a plug-and-play error harness that I developed to help the P1 community with HID retrofits. If you have a question that's not related to the SKBOWE, please see if it fits in one of the other HID threads (above) before posting here or starting a new one.

Lets face it, the OEM halogen headlights in our cars suck. We should all know by now the issues with HID retrofits, and that the DIY solution is not trivial since it takes some soldering and hacks up the CEM harness. I have been PMed dozens of times over the years asking for a better way...

So... I found something really sweet ;) If you are interested in a commercial, plug-and-play (no cut wires!) solution that was designed specifically for Volvo P1 cars (S40, V50, C30, C70) check out:

https://www.skbowe.com/ - Shipping Now! Limited Quantity Remaining

Orders as of October 2017 (82 total): boulderc30, V50toS40, thefisch33, rhags138, persianelf, nhiggins, S40R-by-design, walky_talky20, taskmule, viggen, Puddlepirate56, chrisasdf, Noswal, beachnut, stevien1, evy0311, MJC70, MCRDSM-S40, hq_, et al... *
  • Prototype: #001A (test) #002 (mine), #003 (display unit/open box)
  • Batch 1: #004-#028 CLOSED & SHIPPED (JUL 2017)
  • Batch 2: #029-#050 CLOSED & SHIPPED (DEC 2017)
  • Batch 3: #051-#075 CLOSED & SHIPPED (FEB 2018)
  • Batch 4: #075-#100 - Shipping Now (OCT 2018)
* Don't see your username here? PM me with your SN#



Click here to see SKBOWE Installs!!

rhags138 (007) - Install
mgm7890 (024) - Install + writeup
:thumbup: SirScarFace - Install
:thumbup: Saab - Install

SKBOWEs have shipped all over...

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Useful Snip

For those of you looking for projectors, I put together a reference sheet to help you identify compatible Bosch AL 3-inch "E46" projectors in auctions or at salvage yards:



See the full resolution PDF here: https://www.theeshadow.com/files/volvo/e46/guide/al_projector_guide_v1_web.pdf

You want to look for "Gen 2" projectors, they have the best optics and the wiring is simple. Gen 1 requires a solenoid controller for bi-xenon functionality. All projectors with black plastic rings will fit D2S, the ones with octagon-shaped bulb holders might need a simple modification (bending a small tab) to allow them to take D2S bulbs.

If junkyard hunting and eBay stalking aren't your thing, Nick has been nice enough to hold a few for us:
matched sets of gen 2 projectors... PM if you're interested.
Here are some projector beam patterns:

<a href="https://www.skbowe.com/a/2017/08/01/al-projector-e46-identification-chart-selection-guide-pdf/" target="_blank"><img width="683" height="1024" src="https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-683x1024.jpg" class="attachment-large size-large" alt="" srcset="https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-683x1024.jpg 683w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-200x300.jpg 200w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-768x1152.jpg 768w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-1200x1800.jpg 1200w" sizes="(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 984px) 61vw, (max-width: 1362px) 45vw, 600px"></a>

SKBOWE install is plug-and-play:
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Survey Stats as of May 2017: 87 responses, 82 on board.

VENDOR INFORMATION

We need a reliable manufacturer / distributor for high volume manufacturing of a specialized error canceling circuit designed specifically for the Volvo P1 series. A complete validated production ready design is available. If you are a vendor and are interested in taking on this project, please contact me!
 

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Discussion Starter · #7 ·
Wow keep it up guys, 15 responses in under 8 hours! Have any of you C30 folks cross posted yet?

Nick - there was some discussion a while back (2009) with TRS on machining a bracket for their FX-R projector to mate to our housings. With help from Scott and Kyle, as well as Matt from TRS, we actually got pretty far towards getting a bracket speced. It never made it to production, but if they are introducing a Volvo P1 specific KBOWE, it would make sense to cross-sell their in-house FX-Rs. IIRC the FX-R is much shallower than most OEM setups and would allow extra clearance for the igniter. The R&D is online if you're interested, specifically my FX-R drawing and Scott's dimensioning of the Volvo unit are the final product that could be merged into a adapter plate.

Alternately, I'm sure we could find a 2" OD boot to bundle with the kit that could act as the grommet and allow clearance for the ignitor in the cover. Something like this (off a triumph motorcycle headlight):
http://www.steadfastcycles.com/cart/images/hlight.JPG
 

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Discussion Starter · #9 ·
The FXR's dimensions, however, are no smaller than the E46... Add an igniter and you're interfering with the inner lid structure again - it's tight no matter how you slice it.
Good to know. Yep I agree about the tight clearance, but there is at least 1/4" back there. It would have to be worked out for sure, but a drill template + rubber cap would likely do the trick, even if the wires have to come out a separate grommet.

My point is that DIYing something is effectively guaranteed. It's not a ton of work, but some end-user measuring, cutting, and potentially epoxying may be required.

If the goal is to avoid the OEM-connector DIY of cutting two wires near the CEM, then I assume it's a corollary that you want to limit the DIY here, too. Some best practices/guidelines would be a good idea, especially if you're going to advocate for low EMI igniters immediately adjacent the bulb.
Eliminating all DIY isn't the intention - every HID kit requires at least one hole in the headlight cover. I think the main goal is to avoid having to DIY fabricate/solder/test a KBOWE, secondary goal is to avoid having to cut wires.

The complete kit is a stretch for sure, and would have to come from somewhere like TRS. For the record, I'm not advocating for anything except a commercial KBOWE. If we don't get enough interest to entice a manufacturer, at least you'll know how many parts to order ;)
 

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Discussion Starter · #11 ·
so to clarify, the $450 option uses the stock halogen headlight housings? How much work is required to retrofit?
Yes, it would be a replacement projector assembly. As Nick explained above, it's a good deal of work to swap projectors without cracking the lens seal. Then there will be some DIY hacking to get the dust cap back on without messing with the alignment. Mostly tedious, with the added difficulty of tight spaces and cooked-brittle plastic.
 

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Discussion Starter · #14 ·
Up to 26 responses - but I feel like the C30 folks could really kick this into high-gear...

@MNIWT - any ideas on how to get that crew involved?

P.S. Happy Holidays!
 

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Discussion Starter · #15 ·
Just putting this here for reference:

Using Vehicle sales stats: https://www.media.volvocars.com/global/en-gb/corporate/sales-volumes?year=2006&month=11 also numbers on wiki for S40, V50, C30, put together P1 vehicle sales data:

2004 69,164
2005 86,415
2006 160,950
2007 189,554
2008 165,382
2009 134,217
2010 133,925
2011 106,594
2012 69,885

which is like 1.3 million total, on average 20% of that in the US (225k). Full data here (XLSX, 60kb). With average vehicle age around 11 years it is fair to assume 75% of that (165k) are still on the road. This is substantially more than I expected...
 

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Discussion Starter · #18 ·
Obviously lol, but I personally would hate it if someone who joined that day with 0 posts starts a new thread out of the blue demanding action, especially if they don't have a C30... So I was thinking it'd be more effective if someone who has been around a while would vouch for the effort over here.
 

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Discussion Starter · #21 ·
Thank you sir, I'm monitoring that thread now. We are up to 38 responses - still a bit short. Might need to start thinking bout doing it ourselves (still interested Nick?)
 

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Discussion Starter · #23 ·
Haha, I'll crosspost this to /r/Volvo. I'm still interested, and funny enough with how things are going I may end up being employed in NoVA later this month. Might still be worth pitching something like this to TRS even with low numbers via HIDplanet forums...you might find more P1ers there, too :thumbup:
The last response I got from TRS was on 20 Dec:

Andrew @ TRS (The Retrofit Source)
Dec 20, 16:42 EST

Unfortunately the issue is not necessarily design, but MOQ for ordering a brand new harness as well--I know MOQs are often in the hundreds of pieces for a new harness / wiring component. Do you think there is this large of an interest in them?

Thank you again!
Which is why I started this thread. I subsequently updated them with the results last week but haven't heard back. I figure everything is still in holiday limbo so later this week I'll ping them again.

Not sure I follow with HIDPlanet?
 

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Discussion Starter · #25 · (Edited)

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Discussion Starter · #26 ·
For the record after sending another email (this time pointing to the hidplanet post) I got back

Jamielle (The Retrofit Source) said:
Thanks for your reply and information! I will forward this onto our COO who deals with this kind of product development and see what he has to say.
Hopefully this will start the wheels turning.
 

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Discussion Starter · #27 ·
57 respondents. If this gets to 100 and TRS hasn't committed I'll build a batch myself....
 

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Discussion Starter · #28 ·
Shameless bump/quick update: So the survey is up to 67 responses, which is pretty darn strong.

TRS haven't gotten back to me in over a week and I'm starting to get concerned. If you have an HID Planet account, it wouldn't hurt to say something inthe thread I started there.

If TRS backs out, I have some alternatives lined up - the downside being that the retrofit/full kits wouldn't be available as a bundle. If there is interest in a kit version (including PCB, capacitors, diodes, enclosure - you add wire, solder, silicone) then I can offer that as a reduced-priced option (~$50 shipped) alongside a pre-assembled/tested version (~$99 shipped).
 

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Discussion Starter · #31 ·
What ever happened to this?
My guess is nothing unfortunately
Well, not exactly. I tried to start a Crowd Supply campaign, which looked very promising, but it turns out they don't have manufacturing capabilities (or contacts that have the right setup) which leaves me in the same position as before.

Then, I spent two months working with SparkHID and his OEM in China. All was going well but then they suddenly stopped returning my emails. With any luck, they've ripped off the design and will sell it dirt cheap in the near future :rolleyes: (in all seriousness, I wouldn't be the least bit upset by this outcome)

It's been 6 months and there have been 87 responses (and that's with an aggressive, multi-forum campaign), with only 58 indicating interest. Like I said in the OP, realistically there needs 100+ to have a chance at a place like TRS taking it seriously.

I still think about doing it myself... But at the bare minimum, a batch for 50 cars - that's 100 boxes and ~40 hours of work... Wish I had that sort of free time.
 

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Discussion Starter · #37 · (Edited)
Ok folks, quick update. This has not been forgotten...

I completed the PCB design and BOM (Bill of Materials) a few days ago, with the intention of producing a limited run (100 pairs) for folks here. The prototype PCBs are in the mail, and I put in the connector order (longest lead time - 30 days) to enable a reasonable timeline if this moves ahead.
 

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Discussion Starter · #41 ·
Cool, good to know there are other options. I guess interested folks will be able to find it wherever it gets setup.

No promises but at this point it's looking like $80 shipped w/preorder or $100+shipping after, assuming that there aren't any unforeseen costs (like the above). Should have 4 prototypes (8 units) soonish.
 

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Discussion Starter · #48 · (Edited)
So... I've dropped $2k already (of $6k) :eek: to get these out faster so y'all better put your money where your mouth is...

https://www.skbowe.com/

Threw that together real quick, if there are issues plz let me know. And if you can, help get the word out, the faster we fill the preorders the sooner I can order the caps!
 

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Discussion Starter · #50 · (Edited)
GREAT JOB! Do you happen to have any idea what overseas (Europe) shipping will cost?
Edit: It should be calculating international shipping correctly now.
 

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Discussion Starter · #51 ·
We've got 4 orders so far. International shipping calculation should be working now for those of you overseas - refresh the order page if it still shows the warning.
 
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