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View Full Version : DIY HID retrofit, GC headlights


Robk0000
10-15-2007, 07:38 PM
Yeah, so im getting bored...i cant finish my hood as far as fiberglassing so im going to try something different.

10-15-07
HID retrofit into my stock GC headlights. Not really mine, i bought an extra pair, They are expensive too! Anyways, this will take some time, i just orderd my stuff yesterday so ill be briefing you thouroughly. So as of now i have nothing as far as parts.
what i bought:
2006 Audi S4 HID BiXenon projectors complete
Philips Bulbs
OEM Ballasts and wiring harness

I currently have a fake HIDS which some of you have commented on, they are really blue really bright Although not many people flash at me, i can tell it pisses some people off. PM me if you want details, they will be for sale shortly if this goes well.
The Plan:
first take out the glass lenses off the GC stock headlights, take some measurements and cut the back plastic mounts for the stock H4 bulbs, this way the Big HID projector can fit in perfectly. Nexti want to use the reflector shield as a mold and cut out a piece of balsa wood, steam it up and bend it to the shape of the shield. Then make a frame similar to what you see on a stock S4, see pic.
http://www.cartype.com/images/thumbs/1/audi-s4_front1.jpg
Since these are dual beam projectors i shoudlnt have to do this, but i think it will look much better with a reflector housing on the side of the projector used for High beam, and the HID for low beam. I need to get a small reflective housing, ill probably end up using my stock shield and just cut that down, but its going to be roughly 3"x6" then the HID projector on the side.
After i get that kinda squared away, i want to make an entire frame of blasa wood including where the projector mounts and where the reflecter shield rests on. the balsa wood will only be a mold, im going to place fiberglass ontop of it and make it look really Cool. This being a small project i dont have to worry about using fiberglass, but on my hood if its 40 degrees outside this will take a year to dry. im gonna use a router to make circles that fit around the projector lens, this is going to be ground down to make a slight curve to line perfectly with the projector.
Oh and im trying to get Drivng fog lights with Halos, 3" diameter if anyone has them.



10-16-07
http://i109.photobucket.com/albums/n76/robsimprza00/HID.jpg
10-19-07
Got the Hids in, Tested them, work Great! Cutoff line is insanely Straight http://images.nasioc.com/forums/images/smilies/smile.gif and they are bright as hell. Also took pics so you can see the actual size, Comparing to an 360 game box. No pics of it lite up though.
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0917.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0918.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0919.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0920.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0921.jpg

10-24-07
http://img81.imageshack.us/img81/7392/img0932nu1.th.jpg (http://img81.imageshack.us/my.php?image=img0932nu1.jpg)


Any Suggestions or advice?

Robk0000
10-19-2007, 04:12 PM
10-26-07
Temporary Mounting finsihed on the Left light. I havent checked the lights to see if they are upside down yet so i havent worked on making the backing piece for it yet. So far its coming out great! Ill test them out tomoorw when theres some light, adjust the lights, mark the Mounting points then drill the holes. Also i had to make a big hole in the back of the halo Projector, so im going to attemp to make it look nice with fiberglass. Pics!
http://i109.photobucket.com/albums/n76/robsimprza00/100_1956.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/100_1957.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/100_1958.jpg

11-03-07
Finally Finished with the lights, They are completed! Wohooo! Wiring is almost done as well. Im heading out to Radio SHack to pic up some inline fuses along with more wire to finish this. Heres the Final Light Pics! Also Ill have pics tonight if i get err Done! Also the backing shield is not FIberglass, i decided im not going to do this, it would add about 20 more hours into this project that i do not need. So i used a simple Foam board used for tool organization in a toolbox. Looks great and it was easy to make the two.
I didnt hook up the High beams, im not sure why...anyways, here are the pics of the final product. all the wiring connects directly to the stock harness. I didnt use any relays which made this much easier, but now im left with 4 relays extra and alot of wire. Its pouring when i took these pics, i didnt take any cutoff pics yet, but i can tell you they are almost perfect, i need to drop them down a little and this will Kick Ass!
Lights off:
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0943.jpg
Lights On:
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0947.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0946.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0951.jpg

Nate8409
10-20-2007, 01:53 PM
Just hope you aimed them right..

Robk0000
10-20-2007, 03:10 PM
yeah i know, otherwise I Will Blind the **** outa everything. haha


Cut Off Pics:
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0961.jpg
This one is just sexy:
http://i109.photobucket.com/albums/n76/robsimprza00/IMG_0964.jpg

Robk0000
10-21-2007, 07:05 PM
My mom recommended that i should use clay to make the mold...I think i might try it,then let it dry, then fiberglass over.

Robk0000
10-23-2007, 06:58 PM
Got more parts in today...Relays, 12 stranded wire and some wire wrap to make it look Pretty. i got 50 ft so if someone would like the rest, ill sell it to ya when im done.

Robk0000
10-24-2007, 06:03 PM
More parts again, New High beam lights, and i installed the Halo Rings around them. They look Awesome.

2mprzya
10-24-2007, 06:15 PM
i need some pics man!

Robk0000
10-24-2007, 08:03 PM
updated OP with a picture, looks like photobucket is down.

Robk0000
10-25-2007, 09:36 PM
Just mocked up a frame, both projectors mounted, I did a temporary wiring too, but it didnt fire up, checked it out and my 12v battery in my room is dead...that sucked i was getting worried i ****ed it up. Anyways, lights come in tomorrow, Ill pull an all nighter getting the lens off and make something to mount it up and look sweet!

Post up pics when i get somewher.

2mprzya
10-26-2007, 03:00 AM
you better man! i wish i had some more money to play around with! i really want to do a rear diffuser!

Robk0000
10-26-2007, 05:25 PM
WEll when i get to that diy, come over and we can make a few. already know 2 people that are interested. Anyways, Got the lights and im going to bake them as we speak!

Robk0000
10-26-2007, 08:07 PM
Major Progress BUmp! see second Post!

HamSocks
10-27-2007, 02:18 AM
Looks sick so far. Can't wait to see them all glassed up and sitting pretty in the car.

2mprzya
10-27-2007, 01:34 PM
def looks good man! keep us updated!

Robk0000
10-27-2007, 03:32 PM
Just finished up the balsa mold, going to fuberglass it tomorrow, then finish up the light, Im thinking this light will be done by friday if i work at it everyday. ALso, i mounted it temporarily into my car...WOW Love the look! Its awesome. I cant wait to finish up!

Kevin
10-27-2007, 07:05 PM
looks good man

Robk0000
10-29-2007, 08:49 PM
All i can say after testing these on the car about 30 mins ago is WOW! What a ****ing difference, these lights look sooooooo badass!

2mprzya
10-30-2007, 12:08 AM
pictures!!! now! god!

Robk0000
10-30-2007, 06:21 PM
HAHAHa my brother took two pics, both are black! i dont know how he ****ed up with a point n shoot camera. Your going to have to wait till i get the next one on its way for install. :)

Robk0000
10-31-2007, 08:08 PM
Im going to start the second light today, hopefully ahve this one ready for a test by saturday night. THen sunday ill make the backing shield for both lights so they look Nice!


Anticipation for the end is Making me so ANXIOUS!

Robk0000
11-02-2007, 07:14 PM
Progress bump:
finished the second light as far as mounting, going to make the backing shield tomorrow for the two.
http://i109.photobucket.com/albums/n76/robsimprza00/100_1981.jpg

2mprzya
11-03-2007, 12:06 AM
looks good man. cant wait to see them on the car!

Skidder
11-03-2007, 12:42 AM
Sick... you got skillz

Robk0000
11-03-2007, 07:38 PM
Finally Finished Bump!

check post 2, let me know what you think


:)

2mprzya
11-04-2007, 12:38 PM
tommy likey! tommy want wingy!!!

Robk0000
11-05-2007, 07:07 PM
Updated Post 4 With Cut off pics.

2mprzya
11-05-2007, 08:37 PM
pics of them on the car in daylight? i'd like to see what you did to close up the lights.

Robk0000
11-05-2007, 09:17 PM
I used a simple black foam, it was done temporaily until i get in the mood of fiberglassing. I know it doesnt look awesome, atleast the foam part, but it will hold up till i get the fiberglassing up and running, its just to cold for me to waste my time outside.

http://i109.photobucket.com/albums/n76/robsimprza00/100_1982.jpg
http://i109.photobucket.com/albums/n76/robsimprza00/100_1983.jpg

I dont have any pics of them on the car during the day though.

2mprzya
11-06-2007, 11:15 AM
even with the foam, still looks really good. are you going to be painting the fiberglass black, or are you matching it to the car? reminds me of the morette setup. very nice man!

SilverSubie2.5
11-06-2007, 03:13 PM
Really diggin the look Rob!~ok~

Robk0000
11-06-2007, 05:04 PM
I think i may try matching the color, see how that looks Via Photoshop.

Robk0000
02-21-2009, 04:56 PM
really goood writeup on bugeye conversion


http://forums.nasioc.com/forums/showthread.php?t=1482552

RCKSTR
02-21-2009, 07:48 PM
any for the peanuts? good wright up, I never saw this one before even though its 2 years old:lol: