I've been running the same TSX/TL quad projector setup for 3 years, so I decided to change things up a bit. This is more of a revision of the old setup rather than a completely new setup.

The foglight/high beam section is still the TL projectors with purple tinted clear lenses. Instead of the previous DL50 bulbs, it's now 3000K.

Low beams are now AP1 S2000 projectors. Same Philips 50W DL50 bulbs, and now with 55W HID ballasts (old setup was 50W, really no difference, but the new ballasts are smaller). The cutoff shield was painted blue with duplicolor metalcast paint. The projectors have one extra green spacer behind the lens to give a sharper cutoff.

**edit, my pics got lost, so I'm reposting them.

Projectors mounted.


Aiming the projectors.


Driver side:


Passenger side:



The shrouds for the S2000s is from a combination of OEM BMW E46 2.5" ones and "Type I's" from an online vendor. Creating the shrouds was one of the most difficult part of of all this.



The old setup was CCFL in the clearance strip. This setup is LEDs strips to match my corner lights.
There's one strip in the clearance strip, one in the signal light, and one around the low beam.


The 03-05 signal light buckets don't have a flat area to mount the LEDs, so 06 light buckets that were purchased from IvoryGT were used.


Then a simple plastic lens was used to cover the area. I had some glass lenses that were a close fit, but I was paranoid about getting silicosis of the lungs while dremeling the glass.


The E46 shrouds have a very nice chrome finish that is solid in daylight, but translucent when there's a light source behind it. However, the finish is amazingly delicate. Some of the chrome would rub off with just a light tough.

There's an LED strip behind the E46 shroud. It's supposed to be the same color as the other LEDs, but behind the shroud, it appears more blue.

Testing phase:



The headlight outer lens covers are a set from brand new 06 projector headlights. There's no point putting in S2000 projectors if an old scratched/pitted lens just destroys the cutoff.


Projectors on:


You can see some of the blue from the painted cutoff shield.

And a fun pic of the cutoff during testing phase. I don't remember if the pics were pieced together in the correct order:


Thanks for reading, if you made it this far. Comments appreciated. Unfortunately I can't do headlight mods for other members of the forum, things are too busy for me these days.

more edit*** cutoff pics:






All 4 projectors on:

 

Holy god! Those look amazing! I hope mine turn out half as good.

 

WOW so sick

 

Sweet!!!

 

One of the best headlight mods I've ever seen! Great Work!

 

those are so sick sick looking lights man. Good job. Your work is near flawless!

 

God, why can't I learn this stuff. Prob one of the sickest lights i've seen so far.

 

You've out-done yourself again, E_K. So far, you're the only person that I've seen make an 03-05 headlight look sexy.

 

Sickness. Great work!

 

Looks amazing, love the tint and the final result. Top notch.

 

Looks great! I think a lot of people over do it with the LEDs, yours looks really clean!

Do you know where I can find a new set of headlight outer lens covers?

 

those are fukcing sweet.

 

damn those are sick

 

nice!

 

Thanks for the positive comments everyone. My wife wasn't nearly as impressed.


I bought a set of new 06 projector lights and used the lenses from that set. I color modded the 06 projectors and used that as a temporary set while I worked on this setup.

Here's some pics showing the 3000K lights on with the TL projectors.