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:
http://i1017.photobucket.com/albums/...pse7jcwvbz.jpg


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:
http://i1017.photobucket.com/albums/...psnm7lsipd.jpg


This is my "E46-R / AFS" Evo X specific template that's taped onto the shroud:
http://i1017.photobucket.com/albums/...psxajfecht.jpg


E46-R trimmed with a dremel:
http://i1017.photobucket.com/albums/...ps0fntt2fl.jpg


E46-R fitment into the AFS reflector is about 90%. Trial & error cutting is reduced big time thanks to my template:
http://i1017.photobucket.com/albums/...pssfgforxv.jpg


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:
http://i1017.photobucket.com/albums/...psdkhk679r.jpg


The AFS reflector + Evo X subframe showing the level of hack work required to accomodate the X5 fog light:
http://i1017.photobucket.com/albums/...ps9pqzlvaf.jpg

http://i1017.photobucket.com/albums/...psigdqxhxl.jpg


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:
http://i1017.photobucket.com/albums/...ps0vzfrn9u.jpg

http://i1017.photobucket.com/albums/...psc5i3qnfc.jpg

http://i1017.photobucket.com/albums/...psmwj1syqs.jpg

http://i1017.photobucket.com/albums/...psbeu9gel2.jpg


X5 fog light masked up. All the chrome sanded from the middle section then painted satin black:
http://i1017.photobucket.com/albums/...pswiws0bno.jpg


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.
http://i1017.photobucket.com/albums/...psjg2s809m.jpg

http://i1017.photobucket.com/albums/...psk37jrmhw.jpg

http://i1017.photobucket.com/albums/...psskbs9con.jpg


This is where I'm currently at:
http://i1017.photobucket.com/albums/...psit9xg2az.jpg


Stay tuned for more updates...

I've been researching HIDs / retrofits and came across a few of your threads on HID Planet. Your work is AMAZING, and this looks great.

Do you sell headlights? I'd be interested in a CT9A retrofit.

Nice work as always! Glad to see a new post from you.

For the Evolution logo on the projector would it be possible to use a vinyl decal to make the logo instead of painting each letter?

^^ 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.

any chance you would know how to make the AFS work on a USDM car?

i am still at a lost on where exactly the AFS light is at on the housing.

On the last pic, does this mean you no longer have the AFS function?

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..

Extremely creative. Nice work!

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/

^^ Thanks for the link boss.. Something to think about

The headlights are pretty much done! Just need to seal them up.
The projectors are currently painted black but the mate that I'm selling them to wanted to see Red & White as well before he locked in a colour.

http://i1017.photobucket.com/albums/...psx5hmqurn.jpg

http://i1017.photobucket.com/albums/...psfzzbjfox.jpg

http://i1017.photobucket.com/albums/...psr8xdg2kv.jpg