Custom projector headlights with BMW X5 LED fog lights
#1
Custom projector headlights with BMW X5 LED fog lights
Im currently working on a set of JDM Evo X headlights. Ill be using BMW X5 LED fog lights for the first time. I had always thought about using these fog lights in the Evo X headlight, ever since TheRetrofitSource started selling them.
Specs for this retrofit are:
(Quad low beam setup)
* OEM BiXenon projector upgraded with TRS ZKW-R clear lenses.
* Custom aluminium shields painted black for the stealth demon eye look.
* BMW X5 LED fog lights + E46-R shrouds retrofitted into the AFS reflector.
* EVOLUTION logo painted white on the X5 fog light.
* Full satin black finish.
progress pix:
Opening up the X5 fog light was such a ball breaking job. Got there in the end:
My assortment of paper templates that I use to create custom aluminium shields for projector lenses and also trim shrouds to fit varies headlight types:
This is my "E46-R / AFS" Evo X specific template that's taped onto the shroud:
E46-R trimmed with a dremel:
E46-R fitment into the AFS reflector is about 90%. Trial & error cutting is reduced big time thanks to my template:
New mounting bracket for the AFS reflector created. OEM mounting point circled in yellow will need to be hacked to make way for the X5 heat sink:
The AFS reflector + Evo X subframe showing the level of hack work required to accomodate the X5 fog light:
Securing the E46-R shroud to the AFS reflector, I'm using gardening wire (stripped of insulation before hand) then twist locking it into place:
X5 fog light masked up. All the chrome sanded from the middle section then painted satin black:
The painstaking 2.5hr+ ordeal to create the "EVOLUTION" logo.
The ideal font was extracted from Microsoft Word and the lettering had to be 4.5mm in height. A font size of 20 was right on the money. Once printed on A4 paper I then used green tape to form each letter. This was then peeled of and stuck onto the fog light. I used a 2nd template that was placed above the working area so I could gauge the correct letter spacing.
This is where I'm currently at:
Stay tuned for more updates...
Specs for this retrofit are:
(Quad low beam setup)
* OEM BiXenon projector upgraded with TRS ZKW-R clear lenses.
* Custom aluminium shields painted black for the stealth demon eye look.
* BMW X5 LED fog lights + E46-R shrouds retrofitted into the AFS reflector.
* EVOLUTION logo painted white on the X5 fog light.
* Full satin black finish.
progress pix:
Opening up the X5 fog light was such a ball breaking job. Got there in the end:
My assortment of paper templates that I use to create custom aluminium shields for projector lenses and also trim shrouds to fit varies headlight types:
This is my "E46-R / AFS" Evo X specific template that's taped onto the shroud:
E46-R trimmed with a dremel:
E46-R fitment into the AFS reflector is about 90%. Trial & error cutting is reduced big time thanks to my template:
New mounting bracket for the AFS reflector created. OEM mounting point circled in yellow will need to be hacked to make way for the X5 heat sink:
The AFS reflector + Evo X subframe showing the level of hack work required to accomodate the X5 fog light:
Securing the E46-R shroud to the AFS reflector, I'm using gardening wire (stripped of insulation before hand) then twist locking it into place:
X5 fog light masked up. All the chrome sanded from the middle section then painted satin black:
The painstaking 2.5hr+ ordeal to create the "EVOLUTION" logo.
The ideal font was extracted from Microsoft Word and the lettering had to be 4.5mm in height. A font size of 20 was right on the money. Once printed on A4 paper I then used green tape to form each letter. This was then peeled of and stuck onto the fog light. I used a 2nd template that was placed above the working area so I could gauge the correct letter spacing.
This is where I'm currently at:
Stay tuned for more updates...
Last edited by iEvoVII; Oct 26, 2017 at 03:18 AM. Reason: Correcting title
#4
^^ I went to a sign writing place and enquired about vinyl stickers. They said that their machine wouldn't be able to produce anything that small. Since I know that I have steady hands and I can produce clean results I decided to make them myself..
I'm not a vendor so you'll have to get outside of the forum.
I'm not a vendor so you'll have to get outside of the forum.
#6
I'm not 100% sure but I think the AFS reflector operates on sensors that are speed and steering angle dependant. I don't think USDM CZ4A's would have them.
I also think the pin locations for the AFS wiring are in different locations to DRL wiring on the main 12 pin connector
The AFS reflector is the DRL reflector on the USDM CZ4A's..
I also think the pin locations for the AFS wiring are in different locations to DRL wiring on the main 12 pin connector
The AFS reflector is the DRL reflector on the USDM CZ4A's..
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#8
Evolved Member
Amazing. I admire your skills. But did you know that you can cut both positives and negative stencils super easy? Find a Cricut - Michael's craft shops sells them or someone in your neighbourhood likely has one. http://us.cricut.com/home/
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