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Discussion Starter · #1 · (Edited)
McBee's Jetta Retrofit DIY Guide - Bi-Xenon/D2S - Part I

Intro

This DIY will walk through, in detail, the steps that I took in creating my retrofits. This will be covered in 2 parts. The first part will include disassembling, cutting, test fitting, and bonding the housing. The second part will include mounting, modifying the covers, sealing up, and wiring.

Words of Advice (Thanks to oneskll)

Quote, originally posted by oneskll »
Just wanted to add my $.02.First of all if you want to do a retrofit it will take a lot of time, a good amount of skill, a little knowledge, and a ton of patience!
Here is some advice I wish I had when doing my first two sets, by the third I have pretty much gotten the hang of it.
1) the smaller the projector, the easier it will be (small as in the length from the lense to the back where you place the bulb),
2) test fit everything on every step of the way!
3) if you use jbweld make sure you make it look as perfect as you can before it dries since sanding is a bitch and the little corners are hard to get to (if you need use jbquick and painters tape to stop it from dripping everywhere),
4) line up the housing you make with the blinker/fog this will help you in the long run when adjusting the projector,
5) make sure the projector doesn't touch the housing in the back so you can use the stock adjusters or you will be sorry when you haveto adjust them,
6) take your time!
7) if you do mess up a little satin-black or semi-gloss black will hide your mistakes alot better then gloss or flat which will show all the imperfections
8) make sure you start with a perfect headlights lense, because that is the only thing that is not an easy fix if scratched or messed up.
9) take your time!
10) since you need alot of time and space to do this make sure you have an extra set of headlights to have on your car or you will rush through it and screw it up!
Anyway good luck!

Difficulty Level: Medium; Need to be good with your hands and have a little creativity.

Tools / Parts Used

Lighting



  • (2) OEM E46 Bi-xenon projectors w/ solenoid/cut-off shield (3-wire) and D2S bulb holders - $110 - Use E55 Bi-xenon projectors over the E46 if possible. Makes mounting a lot easier.
    • 2014 Update: There are a lot more retrofit-ready projectors on the market now, that I would opt for those over the E-series projectors. TRS FX-R projectors are a great price point and perform very well.

  • D2S 35W Ballast with built-in ignitors
  • 6000K D2S Bulbs
  • Set of Jetta headlights without fogs - $85


Wiring





Misc.




  • (2) 4X3" PVC Bushing/Reducer - $12
  • JB Weld (Get 2 to be safe) - $12 Fusor is a better choice - JB Weld will crack over time
  • Outdoor silicon (For resealing the headlight lenses)
  • (8) #10 Wood Screws - 1-1/4" - $9 - Pilot hole plus using machine screws is a better method (You can use a nut on the other side of the projector to secure it from forward forces)
  • 3/16" Flat washers (A lot) - $6 - No washers needed with machine screws
  • Krylon Satin Black spray paint - $6
  • Permanent marker


Extras



  • Dual turn signals w/ Amber lenses - $35 (Thanks to Underground VW Parts)
  • 3" Shrouds - $46 off eBay


Tools



  • Wide flathead screwdriver
  • T-15 Torx Drive (For turn signals and fogs)
  • T-10 Torx Drive
  • Dremel or some sort of dynamic cutting device
  • Oven/Hairdryer/Heat gun
  • Solder / Iron / Electrical tape


Total Spent: ~$500

Steps

Part I

Step 1 - Disassemble Headlamps
Step 2 - Cuttin' Sh*t Up
Step 3 - Preparing Projectors for Test Fitting
Step 4 - Test Fitting
Step 5 - Bonding the Housing

Part II

Step 6 - Extras
Step 7 - Mounting Projectors
Step 8 - Modifying Covers
Step 9 - Wiring
Step 10 - Finishing Touches

Step 1 - Disassemble Headlamps:

I am using regular OEM Jetta headlamps, without fogs.


Start by removing the metal clips that help to hold the lens to the housing:

Then you need to remove the covers on the back along with rubber drain hoses:

Next remove the wiring harness to the turn signals and low/high beam bulb. Then pull the bulbs out.

Use either a heat gun/hairdryer or oven to loosen the sealant. I used the oven. Preheat to 175-200F, then put in one headlamp. Lens should not make contact with anything in the oven. I also used a cookie sheet to sit the headlamp on. Leave it in for 60-90sec, pull it out and use a wide flathead screwdriver and start to pry apart one corner of the lamp. Once you get it to where you can get a good grip on it, start using your hands to pull the lens apart from the housing.


Now we need to separate the reflector shield from the housing. There are to 2 "ball-joint" like fasteners and a lower faster that loosens with a twist. You can go about this two ways. The first is what I recommend:

-Completely unscrew the 2 top adjusters all the way, twist the lower joint loose and pull the shield.
OR
-They are held in by ball-joints. So, you can just pull and they will release, but it's an easy way to break the adjuster joint and/or the shield. I'd just go with the option above if you can.





On the reflector shield, remove the turn signal housing/lens by removing the 3 T-15 screws.


Then remove the black supporting bracket by unscrewing the T-15 screw:

Then release the security clip on the other end of the bracket and it will come off with a little pulling:

On the headlight lens you need to remove the surround for painting later. There are 6 T-10 screw holding it to the lens. Remove those and it will come out in 2 pieces.



Step 2 - Cuttin' Sh*t Up
Taking the 3" ID PVC connector start to take measurements and trace an outline of the outside diameter of PVC connector onto the back of the reflector shield.

I used a Dremel to make smooth and precise cuts. Once the hole is cut put the PVC connector up to it and start to grind away at the hole until the PVC connector can slide through.




Step 3 - Preparing Projectors for Test Fitting
Bought my OEM E46 projectors and bulb holders off eBay. Received them 3 days later in great condition:

I started by disassembling them to remove the lenses and start to get measurements. There are (4) T-15 torx screws holding the lens and frame. Remove these bolts carefully, not to drop the frame and lens. Then separate from the rest of the housing:

Next, on the inside of the lens frame you can see how the lens is being held into place. First, push back the safety bends with a pair of pliers or if your a badass, with your fingers:

Now, you will see the metal safety ring sitting on the lens. Simply go for the middle of the ring (opposite of the ring gap) and gently pull up. Continue around the ring until it comes out. Then, using your fingers hold the lens in place while you turn the frame 180* and gently lift it off the lens:

I then cleaned the lens and made sure there were no scratches or breaks, wrapped them up and put them in safe keeping until later on:

Once they are separated the solenoid and cut-off shield will easily slide forward and off the housing:


Step 4 - Test Fitting
Taking the lens frame and a 3" ID PVC sit it inside to see how it is going to fit. I needed to make 2 notches in the PVC connector because the lens frame has 2 legs that extrude past 3" in diameter.


Now to test fit the projector housing. I will be using 1-1/4" #10 wood screws and 3/16" washers to mount it in place.
Note: I painted the PVC fittings before test fitting; which shouldn't be done because of scratching/blemishing the paint while test fitting.

2 of the holes line up to the slot on the PVC and 2 hang over a little. In order to mount the other 2 I used some brackets - same brackets that hold the 1.8T engine cover to the valve cover - and used a metal grinder to grind away whatever needed for it to sit flush.


Now to paint whatever needs to be painted. I will be painting the PVC connectors, lens frames, reflector shield and surrounds. I am using Krylon Satin Black. I lightly sanded the surfaces before painting. Then a couple coats of paint should be good.

During drying times I cleaned up the lenses.I used a flathead screwdriver to scrap away most of it. Then finished it off using some GooGone. Finally I washed the lenses and this is the result after 1 round of polishing.



Step 5 - Bonding the Housing
I first sat the PVC fitting in the reflector housing. Then I made sure the PVC was in the correct orientation; both horizontal and vertical. Below shows correct orientation.


Once the orientation was set I mixed up with JB Weld and applied all the away around. This coat was kind of thin, so I will be putting another layer on.
Note: JB Weld will crack over time. It is better to use an automotive repair adhesive like Fusor.


Once the JB Weld has set up I added another coat of paint.
I have also recently decided to grab some shrouds off eBay. Grabbed them for $46 shipped.

Since the shrouds will require me to sit the lens and frame further out the front of the PVC fitting I needed to cut complete notches. I also needed to sand down the lip on the PVC fitting so it was flush with the rest in order for the shroud to fit properly.



Then I needed to shave a little off the inner sides in order for the cut-off shield to drop without interference. It just takes a lot of testing, marking, and cutting. These are not the easiest projectors to deal with.


Continue to Part II



Modified by McBee at 5:29 PM 2-3-2010
 

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Re: McBee's Jetta Retrofit DIY Guide - Bi-Xenon/D2S - Part I (McBee)

great 1000th post...always wished i had more free time to do this...
 

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Re: McBee's Jetta Retrofit DIY Guide - Bi-Xenon/D2S - Part I (christanand)

Quote, originally posted by christanand »
great 1000th post...always wished i had more free time to do this...

x2
and now that i see how easy it is i may have to do this myself come summer time http://****************.com/smile/emthup.gif
 

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Re: McBee's Jetta Retrofit DIY Guide - Bi-Xenon/D2S - Part I (Greg_J)

I'm saving this thread cuz i'm either gunna send my headlights to 99.5 or do it myself, thanks for the great post! http://****************.com/smile/emthup.gif
 

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Re: McBee's Jetta Retrofit DIY Guide - Bi-Xenon/D2S - Part I (J-tec)

http://****************.com/smile/emthup.gif Great write up.
For all the noobs putting drop-in HIDs in reflector housings, take note.
This is how it's suppose to be done!
 

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Re: McBee's Jetta Retrofit DIY Guide - Bi-Xenon/D2S - Part I (tonyb2580)

i cant believe those use to be my headlights. im glad to see better plans for them. good luck with the retrofit. http://****************.com/smile/emthup.gif
 

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Awesome! Im gonna tackle this myself! Anyway to keep the headlights "stock" in color...maybe sprayin them with chrome or greyish paint? anyone got a better idea?
 

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Discussion Starter · #9 ·
Re: (EURjus2slo)

Thanks for all the comments.
Quote, originally posted by EURjus2slo »
Awesome! Im gonna tackle this myself! Anyway to keep the headlights "stock" in color...maybe sprayin them with chrome or greyish paint? anyone got a better idea?

Check this thread out: http://forums.vwvortex.com/zer...age=2
First picture on page 2.
 

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Re: (EURjus2slo)

Quote, originally posted by EURjus2slo »
Awesome! Im gonna tackle this myself! Anyway to keep the headlights "stock" in color...maybe sprayin them with chrome or greyish paint? anyone got a better idea?

The problem is, that the pvc will need to be painted, even if you kept the original chrome inside the headlights perfect, there would still be that. You could get a shroud off ebay thats 3" and will complete the look, but most times retrofits get messy and things need to be sanded and painted. If you JB weld you have to sand first.
Making a finished retrofit chrome would be very very expensive. No chrome paint is really going to match, but a metalic silver wouldnt look bad. Heres what I did to my old set:

I left that piece attached to headlight chrome and everything else painted black
 

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Re: (pyro2001vr6)

wow man, good stuff for sure!!! i am FOR SURE saving this thread (and the next one you make) so i can do this to mine http://****************.com/smile/emthup.gif
 

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FV-QR

Impressive, I didn't think anyone would ever take the time to make a DIY for this.
 

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Re: (Windex921)

Straight forward DIY! This is really great for the bunch of us that are a little hesitant to try this without a good DIY! ... waiting for part II...
 

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Discussion Starter · #15 ·
Re: (Nightrider)

I have decided to either go with dual turn signals or adding fogs to the blanks below the single turn signal.
Let me know if you have any parts that you want to sell for the things in bold under the parts list.
Thanks for the comments everyone



Modified by McBee at 10:59 AM 1-11-2009
 

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Discussion Starter · #17 ·
Re: (StBarnabas)

Just purchased some shrouds off eBay for $46. Planning on leaving the chrome, outer ring and painting everything below it to match the rest of the housing.




Modified by McBee at 2:19 PM 1-15-2009
 

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Re: (McBee)

I really want to do this... I hope i dont **** it up.
good DIY... http://****************.com/smile/emthup.gif
 

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Nice Retro... When I get around to doing a set for my jetta, I was thinking of getting chrome paint then going over that with satin clear or something for a silver satin yet shiny finish.
 
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