My custom headlights: Quad Bi-X Projector, Horseshoe Orions, Frosted Fins
#1
Members
Senior Members
Thread Starter
![Default](https://5series.net/forums/images/icons/icon1.gif)
I couldn't resist cutting my headlights open. The oem light output is terrible, the angel eyes are a joke, and who likes cookie-cutter chrome?
I sourced most of the parts from TherRetrofitSource.com, I used them for an FX-R retrofit in my E39 a few years back with great results, the company has expanded their product range and refined experience for their customers. Also if you are a sucker for deals make sure to check out their clearance section, both my STI-R lenses and Mini H1s were "b-stock".
Here are the goods:
- OEM Bi-X Projector. lens swapped with STI-R spaced 8.7mm
- MH1 Projector
- 9006 HD Relay
- Morimoto 35w DSP ballast
- Morimoto 5Five 5k bulbs
- DDM 55w ballast, 5k bulbs
- E9X Orion V2s Customized: circuit boards cut, wiring flipped.
- High Temp Black and Aluminum paint
Notes:
- I don't think the STI-R lenses are absolutely to best for this application, TRS recommended using D2S 3.0 lenses which are usually sold as a whole projector not individual lenses. The optic details could not be shared so I can't confirm their performance but if anyone goes this route, get the D2S lenses and report back, I am led to believe they will NOT require spacing.
- The STI-Rs have a dissipating beam cutoff at greater widths BUT my setup does create quiet a bit of blue/intensity light at the cutoff. Although it does not serve a functional purpose it is widely known for being cool by everyone from high-school kids running 8k hid bulbs in halogen housings to automotive lighting aficionados.
- Since the MH1s are located in a fixed housing, my headlights are now adjusted by tilting the actual housings themselves, thankfully the adaptive headlights will compensate with auto-leveling.
- I wanted to wire my MH1s into my fog light wiring so I could run the projectors individually if desired, since I have an oem M5 front end I think some of my wiring harness may have left with my regular bumper, I will look into this further.
- There is not a lot of info out there about headlight retrofits since most people don't cut open their oem E6X headlights and the companies who do this service for a fee were not helpful, they either never responded or said they were not willing to divulge information so be prepared to research a ton and spend a few days to creep your way through this project.
- Light output is insane, I can't wait to get some better bulbs into the equation.
Hope this inspires someone,
Evan
Here we go...
![](https://lh5.googleusercontent.com/-B1ivVFKyi_E/VCR5-jD9aCI/AAAAAAAAFtQ/QNVzi6XxklA/w1215-h911-no/IMG_2835.JPG)
I can't imagine to the poor German that designed this...
![](https://lh6.googleusercontent.com/-j-_1C3R3l4A/VCy_MO8CDRI/AAAAAAAAGCg/zCYOn0zkh0o/w1215-h911-no/IMG_3047.JPG)
Workspace.
![](https://lh3.googleusercontent.com/-pyuErg2UPzI/VCR5_s5F-SI/AAAAAAAAFtQ/pIALQgltuB8/w1215-h911-no/IMG_2841.JPG)
Tuning the oem projector.
![](https://lh3.googleusercontent.com/-nl74oTddopE/VCjflIAz5OI/AAAAAAAAF2I/Al_Zqc4GjPM/w1215-h911-no/IMG_2999.JPG)
STI-R left oem right
![](https://lh4.googleusercontent.com/-3i10VXqViDU/VCjfikUMTlI/AAAAAAAAGcY/F-TEo863xT8/w1215-h911-no/IMG_2984.JPG)
Chrome stripped off the shrouds.
![](https://lh6.googleusercontent.com/-r1hqSgocZaM/VCjfgBN8hTI/AAAAAAAAF3M/PGvA6IySQcU/w1215-h911-no/IMG_2869.JPG)
Painted Aluminum
![](https://lh4.googleusercontent.com/-2TihnU0oVDc/VCjfg2ZnKwI/AAAAAAAAFzU/Wab_njb7fQo/w1215-h911-no/IMG_2872.JPG)
The original design. I didn't like how the inner shroud looks so large when painted a solid color (non-black). It visually weighs the headlight in an odd way.
![](https://lh3.googleusercontent.com/-zj-6t1Tj7pY/VCsbfazpSaI/AAAAAAAAF78/VCtbGD7fwhk/w1215-h911-no/IMG_2910.JPG)
V1
![](https://lh5.googleusercontent.com/-CtUBNddcNCM/VCR6GAjxOOI/AAAAAAAAFrE/MKwbvNke-8A/w1215-h911-no/IMG_2878.JPG)
Love this photo
![](https://lh4.googleusercontent.com/-Qpb_ZKvADZI/VCR6QjFaIUI/AAAAAAAAFs4/WcVEQDpNXZ0/w1215-h911-no/FullSizeRender%2B%283%29.jpg)
Frosty!
![](https://lh4.googleusercontent.com/-Pa8BOpSZrXA/VCsbhOaZoOI/AAAAAAAAF8Y/UY8-pfTbE28/w1215-h911-no/IMG_2914.JPG)
The spacer that saves the day.
![](https://lh5.googleusercontent.com/-xK3eFfL4D-g/VCsbjTo1j9I/AAAAAAAAF9A/oo9J4HxTZl8/w1215-h911-no/IMG_2919.JPG)
MH1 in angel eye bowl.
![](https://lh6.googleusercontent.com/-4cUQap-voeY/VCsbjpzr9CI/AAAAAAAAF9I/yJAENdkvB70/w1215-h911-no/IMG_2920.JPG)
Orion V2s after I got my hands on them.
![](https://lh4.googleusercontent.com/-Qm7ulbns2gM/VCjfkNpwUAI/AAAAAAAAF2U/RDJpGg2o1JM/w1215-h911-no/IMG_2989.JPG)
Getting there...
![](https://lh3.googleusercontent.com/-L-L2lwyG-hE/VCjflVS8RNI/AAAAAAAAF0k/7MYrMoegg-M/w1215-h911-no/IMG_3003.JPG)
All butyled up for resealing. This is the color combo I ended up with.
![](https://lh5.googleusercontent.com/h7lpTD9gWwi_xv0I6GnnKjFnE8F8OL2Sq5mrKzRuFzE=w1215-h911-no)
Sealed up.
![](https://lh3.googleusercontent.com/-15RuNzIvN5w/VCrXBlqpakI/AAAAAAAAF4o/CQ4OCjF-dX8/w1215-h911-no/IMG_3030.JPG)
Make sure to polish your headlights, before:
![](https://lh3.googleusercontent.com/-4DCH9JpGoqU/VCy_KOM_XiI/AAAAAAAAGCg/lITbaMh_YnQ/w1215-h911-no/F1.JPG)
After:
![](https://lh3.googleusercontent.com/-FT9ujdm9CUY/VCy_Jo3P9sI/AAAAAAAAGCc/kPSxoq5ZKMQ/w1215-h911-no/F2.JPG)
Completed:
![](https://lh4.googleusercontent.com/-enEUpx3eIc4/VC4R_OWapmI/AAAAAAAAGNw/Qxifzsam61I/w1215-h911-no/IMG_3131.JPG)
Cars and Coffee SF
![](https://lh6.googleusercontent.com/-VhNM4OmVdM0/VDP_2HTjcaI/AAAAAAAAGbk/oqa2Jd2Gsco/w1215-h911-no/IMG_4453.JPG)
With some white on white
![](https://lh3.googleusercontent.com/-hC9eDOge6ao/VDCy3bzkQWI/AAAAAAAAGQQ/otr25oE2yDE/w1215-h911-no/IMG_4455.JPG)
Orions at night
![](https://lh4.googleusercontent.com/-cx_YFM7QOlo/VCy_PovoBOI/AAAAAAAAGAI/6RvbVVqp-to/w1215-h911-no/IMG_3107.JPG)
Beam shot
I sourced most of the parts from TherRetrofitSource.com, I used them for an FX-R retrofit in my E39 a few years back with great results, the company has expanded their product range and refined experience for their customers. Also if you are a sucker for deals make sure to check out their clearance section, both my STI-R lenses and Mini H1s were "b-stock".
Here are the goods:
- OEM Bi-X Projector. lens swapped with STI-R spaced 8.7mm
- MH1 Projector
- 9006 HD Relay
- Morimoto 35w DSP ballast
- Morimoto 5Five 5k bulbs
- DDM 55w ballast, 5k bulbs
- E9X Orion V2s Customized: circuit boards cut, wiring flipped.
- High Temp Black and Aluminum paint
Notes:
- I don't think the STI-R lenses are absolutely to best for this application, TRS recommended using D2S 3.0 lenses which are usually sold as a whole projector not individual lenses. The optic details could not be shared so I can't confirm their performance but if anyone goes this route, get the D2S lenses and report back, I am led to believe they will NOT require spacing.
- The STI-Rs have a dissipating beam cutoff at greater widths BUT my setup does create quiet a bit of blue/intensity light at the cutoff. Although it does not serve a functional purpose it is widely known for being cool by everyone from high-school kids running 8k hid bulbs in halogen housings to automotive lighting aficionados.
- Since the MH1s are located in a fixed housing, my headlights are now adjusted by tilting the actual housings themselves, thankfully the adaptive headlights will compensate with auto-leveling.
- I wanted to wire my MH1s into my fog light wiring so I could run the projectors individually if desired, since I have an oem M5 front end I think some of my wiring harness may have left with my regular bumper, I will look into this further.
- There is not a lot of info out there about headlight retrofits since most people don't cut open their oem E6X headlights and the companies who do this service for a fee were not helpful, they either never responded or said they were not willing to divulge information so be prepared to research a ton and spend a few days to creep your way through this project.
- Light output is insane, I can't wait to get some better bulbs into the equation.
Hope this inspires someone,
Evan
Here we go...
I can't imagine to the poor German that designed this...
Workspace.
Tuning the oem projector.
STI-R left oem right
Chrome stripped off the shrouds.
Painted Aluminum
The original design. I didn't like how the inner shroud looks so large when painted a solid color (non-black). It visually weighs the headlight in an odd way.
V1
Love this photo
![](https://lh4.googleusercontent.com/-Qpb_ZKvADZI/VCR6QjFaIUI/AAAAAAAAFs4/WcVEQDpNXZ0/w1215-h911-no/FullSizeRender%2B%283%29.jpg)
Frosty!
The spacer that saves the day.
MH1 in angel eye bowl.
Orion V2s after I got my hands on them.
Getting there...
All butyled up for resealing. This is the color combo I ended up with.
Sealed up.
Make sure to polish your headlights, before:
After:
Completed:
Cars and Coffee SF
With some white on white
Orions at night
Beam shot
#5
Members
Senior Members
Thread Starter
#6
Senior Members
Join Date: Jan 2011
Location: UpState SC
Posts: 2,348
Likes: 0
Received 3 Likes
on
3 Posts
My Ride: 2008 535i LCI with sports/premium package, Sports trans with paddle shifters, CF emblems, JB4 Software, Dinan Exhaust, Navigation, M5Tech body kit, Carbon wrap interrior trim and CIC Controller.
![Default](https://5series.net/forums/images/icons/icon1.gif)
Very nice!
#9
Members
Senior Members
Thread Starter
![Default](https://5series.net/forums/images/icons/icon1.gif)
It is actually an intercooler and an aftermarket one. It is meant for a 335i but I retrofitted it to my E61. It is not PNP and it is much better than stock, almost x2 efficient.
Here is how I fit it: How To: Fit a 7" VRSF Intercooler to your E6X N54 chassis - N54Tech.com - Your Source for International Turbo BMW Racing Discussion
Evan