DIY: 2006 Projector Cutoff/Color Mod
 

DISCLAIMER: TRY THIS MOD AT YOUR OWN RISK, THIS IS A MODERATE/ADVANCED MOD, THEREFORE A LOT OF DETAILS ARE LEFT OUT, MOST OF WHICH ARE SELF-EXPLANATORY.

BEFORE YOU PROCEED MAKE SURE YOU UNDERSTAND: THE MORE COLOR THERE IS THE LESS LIGHT OUTPUT (FOREGROUND) YOU HAVE. ALSO WITH SIGNIFICANT COLOR BAND, YOU LOSE THE FLICKERING EFFECT THAT YOU SEE IN BMW/MERCEDES, SUCH THAT YOUR LIGHTS WILL APPEAR SOLID PURPLE OR BLUE INSTEAD OF A QUICK SPARK OF BLUE THAT YOU SEE IN OTHER CARS.

To get to the projectors, please refer to the DIY by PeteNJ
https://g35driver.com/forums/body-interior-exterior-lighting-diy/75211-diy-projector-retrofit.html

Note for 06s, simply use a wrench set with 8mm sockets, turn counterclockwise on all 3 bolts until the projector is free, also remove igniter by turning counterclockwise and pull away from the projector. Make sure you disconnect the solenoid power clip at the bottom of the projector.

To make it easy on yourself, remove the reflector bowl by removing the 4 screws in the rear of the projector.

Click on thumbnails for larger pictures.

After removing the projector from the headlights.

Remove the shroud that's holding the Lens in place. Use a flat head and insert into the indents.
https://smg.photobucket.com/albums/v...3333-K1024.jpg

SKIP the next step for first timers

After removing shroud and lens, you will see the glare guard that needs to be removed. Caution: This step proved to provide additional light, but also some glare effect. Experiment at your own risk

https://smg.photobucket.com/albums/v...3335-K1024.jpg

A drill press is used in this DIY to ensure a clean cut of the glare guard.

https://smg.photobucket.com/albums/v...3336-K1024.jpg

It should look like this when done.

https://smg.photobucket.com/albums/v...3337-K1024.jpg

The output should look like this when done. (Phillips 85122+ used)

https://smg.photobucket.com/albums/v...3339-K1024.jpg

Second part of the mod is replacing the Fresnel lens that comes factory and replace it with a clear one from TSX projectors. (ebay for about $150~$200 ) OR HIDplanet.com and search on the buy/sell/trade forum for 2.5" clear lenses. TSX works best

Stock
https://smg.photobucket.com/albums/v...3354-K1024.jpg

To remove the lens from the TSX projectors, use a set of pliers and pull the clip towards you and upwards.

https://smg.photobucket.com/albums/v...3353-K1024.jpg

Simply place the clear lens from TSX and place it in the factory projector and reinstall the factory shrouds over it. Make sure the shroud is secure and the lens does not rattle or shift.

Clear lens installed
https://smg.photobucket.com/albums/v...3355-K1024.jpg

The output with removed glare guard and clear lens.

https://smg.photobucket.com/albums/v...3346-K1024.jpg

Now we will proceed to bend the factory cutoff shield.

Photo 1
https://smg.photobucket.com/albums/v...3365-K1024.jpg
Photo 2
https://smg.photobucket.com/albums/v...3364-K1024.jpg
Photo 3
https://smg.photobucket.com/albums/v...3363-K1024.jpg


As you can see in photo 2, the shield is 90 degrees up right, and for softening the glare reasons, the factory projector came with dual cutoff. The shield both needs to be changed.

This mod requires some playing around with the shield to really get the right result.

Step 1: To make it sharper, push the front shield downwards(or dremel off), so it's not in the view of the light path, it's the one closer to you in photo 3.

Step 2: Refer to Photo 1, curve the shield more so it appears to be more of a semi circle and push it slight forward.

Step 3: Modify the Metal Guide piece so it looks like the following. This allows for the shield to sit higher than stock and eliminate the previous vibration problem from removing the guide all together.

This creates a number of issues, the vibration is not completely eliminated and I think it's the nature of the design, secondly, the spacing of the guide creates a mountain below the cutoff that is not as well lit as the rest, this became more prominent when leaving the guide in place.

Attachment 247497
Attachment 247498


Step 4: (THIS STEP NO LONGER NECESSARY IF YOU KEPT THE METAL GUIDE PIECE IN )

The stock shield uses a metal tension mechanism to pull the solenoid upwards, and when power is applied, the solenoid pulls the shield down, creating high beams. The problem was the factory shield was held down partially by the metal spacer, by removing this spacer, the shield springs upwards and holding too much tension on the solenoid, preventing the pulling down to happen.

Solution is to remove the shield by unscrewing the bottom two screws and push the shield downwards, so it appears more of an oval. Make sure you push down with two hands and ensure both sides are even. Reinstall the shield and test it out.
https://img.photobucket.com/albums/v...h_DSC03448.jpg

Now the result should be like this:

Attachment 247499

Night shot

Attachment 247500

Attachment 247501

Attachment 247502

http://img.photobucket.com/albums/v6...s/DSC_0980.jpg

Attachment 247503





Finally you can get the color you want.


Purple
https://smg.photobucket.com/albums/v...3366-K1024.jpg
Blue
https://smg.photobucket.com/albums/v...3367-K1024.jpg

Video
http://img.photobucket.com/albums/v6...MOV03368-1.jpg
http://img.photobucket.com/albums/v6...h_MOV03446.jpg

This is an awesome writeup, I'll be trying this sometime in the next few months once I get a few days off. No need to mill the projector for the lense like the other guy did?

Also, can you take some pics showing the high beam pattern, I just want to verify that the bixenon feature still works and the light output with the clear lense on high

Is the mod about the same with the TL projectors? My S2000's are perfect but the TL ones are not as sharp.

with TLs you need ZKW clear lens and that takes care of it, it might not be sharp up close, but it focuses far away.

I didn't install it on the 06 harness for testing purpose, but I will test it out soon.

Thanks!

I'm not sure if the ones I got came with the clear lens or not. Is there any easy way to tell without another TL projector to compare them to?

yeah..look at http://smg.photobucket.com/albums/v6...3354-K1024.jpg

see how there are rings over the dome, yours most likely looks like that. You will need to get clear lenses that are from ZKW projectors.

basically lenses from these http://cgi.ebay.com/ebaymotors/2005-...spagenameZWDVW

but this guy is overpriced. You might have to look around for deals.

Notice this is fresnel
https://i51.photobucket.com/albums/f...images0005.jpg

and this is clear

http://students.washington.edu/weita...9/DSC03894.JPG

How much would you charge to do this if I sent my 06 Headlights your war...And where are you located?

Pm sent

Thanks again, mine are fresnel.

Time to open up my lights again. :rolleyes:

yeah...that's not that much fun...

very nice write up.... wish i had the time to mod and play with it

Do sedans come with projectors?

So do you purchase the whole TSX projector and remove the lense? Any idea if the stock fresnel lense will fit back into the TSX projector body so I can resell that to recoup some of my cost or to use for the lower bowl?