DIY: The Retrofit Source (TRS) Retro-Quick System - Burnt ZKW Bowls - Projector Retrofit doityourself

[TomTomTuning]

This is my first DIY, so be warned... I know I missed a few photos, I'm terribly sorry.

I used the following tutorial for taking the headlights out and apart.

How to remove headlights from car: (By Xion Unjust)

http://www.youtube.com/watch?v=2BFQu1dDU1o

How to take the headlights apart: (By jdinisio)
His are AL headlights not ZKW but the internals are very similar.

http://www.youtube.com/watch?v=SaQfWLe528U

__________________________________________________

Here is where my DIY really begins:

Here is a very easy and cost solution for burnt ZKW projector bowls.

Items needed: $214 total (Free Shipping)
RETRO-QUIK: BMW E46 / ZKW (http://www.theretrofitsource.com/complete-retrofit-kits/morimoto-retro-quik-system-bmw-e46-zkw-lights-only.html#.VBWwSUsbxEM) (Projectors and Brackets Only): $179.00 (Link Updated)
Value E46R Shrouds (http://www.theretrofitsource.com/product_info.php?products_id=131): $15.00
JB Weld Epoxy (http://www.theretrofitsource.com/product_info.php?products_id=31618): $5.00

This system uses Hella EvoX-R Projectors.
I also installed a set of 6000K bulbs.

Step 1 - Remove the four trox screws holding the projector bowl/lens to the bezel.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8753-Edit-1.jpg

Step 2 - Remove the lens from the shroud by pushing the two plastic tabs in, one on the left and one on the right.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8755-Edit-2.jpg

Here is everything taken apart, notice one of the holes does not go all the way through. The passenger side headlights requires that you drill that out, however the driver side is fine.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8757-Edit-3.jpg

Step 3 - Remove the rubber spacers and put them to the side, you're going to use them later. I used one of the screws to easily remove them.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8759-5.jpg

Step 4 - The existing holes are not big enough, so use a drill bit that's slightly larger then the supplied screws. I didn't pay attention to what size I used, sorry.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8761-6.jpg

At this point you can drill through that fourth hole (as previously mentioned).

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8763-8.jpg

Test fitting the screws, note you'll only be using 3.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8762-7.jpg

Step 5- Use a dermal to cut notches out of the bezel to allow for the high beam flicker module to fit.

Step 6- Put the rubber spacers back in, then the supplied black spacers and screws.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8764-Edit-9.jpg

Step 7 MISSING PHOTO - Mount the projector to the bezel and screw the 3 screws to the supplied nuts.

(since I forgot to take a photo of the projector mounted to the bezel, here is a detailed photo of what the projectors look like)
http://i9.photobucket.com/albums/a98/boostd240/6ypezyny-1.jpg

Step 8 - Use the dermal again to cut out notches to the top of the E46R shrouds.

(Old photo of a shroud TRS accidentally sent me, my notches were similar to this.)
http://i9.photobucket.com/albums/a98/boostd240/RUk0PwEh.jpg

Step 9- Mix your epoxy (I got clear epoxy from Amazon).

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8768-13.jpg

Step 9 - Apply the epoxy to the inside of the shroud and attach it to the bezel/projector. I used tape to hold it in place while it dried.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8767-12.jpg

Step 10 - Cut the OEM high beam flipper plug, and solder the new leads.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8765-11.jpg

Put it all back together and reinstall the headlights onto the car.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8774-15.jpg

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/885C9194-18.jpg

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/885C9184-16.jpg

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/885C9185-17.jpg

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/885C9200-19.jpg

[Avetiso]

Looking great, Tom! Thanks for the contribution.

[E_Rak]

Awesome DIY. A nice summary for those looking to go this route rather than AL.

[TomTomTuning]

I do admit I expected it to be a bit more "bolt-on" but considering the previous options, this was fairly easy.
Just a tiny bit of drilling and dremaling.

Light output is amazing compared to before. I really should have taken before photos the night before but everyone with burnt bowls knows the story.
Also, remamber I went to 6000K bulbs, so brightness is less then OEM 4300K bulbs.

[danewilson77]

Well done Tom.

Sent from my Samsung Galaxy S4

[wertyu78]

Great! I did the FX-R 3.0 conversion this time last year. Best $500 I've spent on the car.


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[trancenation]

Well Done Tom! This will be a great help when I do my headlights!

[cakM3]

Looks awesome Tom! Thanks for sharing your DIY :thumbsup

[TomTomTuning]

Thanks everyone.
Here is a photo of the burnt bowls.

10073


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[cakM3]

Tom, I'm not surprised to see them burnt like that...you would think BMW would recognize a safety-related issue like this and do the right thing :facepalm


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[MiniD]

Going to order this same kit. Thank you!

[TomTomTuning]

Going to order this same kit. Thank you!

No problem, let me know if you have any questions. The kit did not include instructions...


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[MiniD]

No problem, let me know if you have any questions. The kit did not include instructions...


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What kind of bulbs did you use?

[TomTomTuning]

What kind of bulbs did you use?

Cheap 6000k bulbs from Khoalty, they seem decent so far but I might order 5000k Morimoto XB35 or 4300k Philps 85122+ from TRS...


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[Hornung418]

Can I notch my existing shrouds...or will they even fit? I'm doing this project today.

GS3 + TT4

[aurelius]

I did the FX-R 3.0 conversion this time last year. Best $500 I've spent on the car.
now Free (http://tapatalk.com/m/)

Lightwerkz? So you sent your headlight assemblies to them and they did what?

[wertyu78]

Lightwerkz? So you sent your headlight assemblies to them and they did what?

No, I didn't use them. I shipped my headlight assemblies to "The Retrofit Source (TRS)" and Val did the cutting of the frames and installed the projectors. Then I drove to their warehouse and installed headlights. That's when I went home and played with shroud colors. Check my build thread.


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[Hornung418]

http://img.tapatalk.com/d/13/09/13/6e7yzety.jpg

Left side replaced/ right side burnt.

GS3 + TT4

[TomTomTuning]

http://img.tapatalk.com/d/13/09/13/6e7yzety.jpg

Left side replaced/ right side burnt.

GS3 + TT4

Nice, how did the install go for you? Did you get the other side finished?

[Hornung418]

Nope needed to get to class. I was unaware that the projectors would need different shrouds...so I ordered the value e46r and some CBIs for another $200 into the already cheap DIY. I will finiah the knstall when I get the shrouds and bulbs.

GS3 + TT4

[Hornung418]

TRS is really pissing me off. First the option to select the bulbs even though I didn't purchase the whole kit. Now I just received the replica shrouds and it didn't come with centric rings...they only come when you purchase projectors. This site is scamming me out of every dollar I have. This whole thing was supposed to affordable and quick and now I have to wait even longer to finish my lights because the morons running the show over there have to include asterisks hidden in the wall of text talking about their product.

I'm super bummed. These lights will be for sale eventually. They will be better in every way than your ZKWs, but the hassle of DIYing isn't worth it. ALs with ZKW lens swap is unequivocally the best option for your ZHP.

[TomTomTuning]

TRS is really pissing me off. First the option to select the bulbs even though I didn't purchase the whole kit. Now I just received the replica shrouds and it didn't come with centric rings...they only come when you purchase projectors. This site is scamming me out of every dollar I have. This whole thing was supposed to affordable and quick and now I have to wait even longer to finish my lights because the morons running the show over there have to include asterisks hidden in the wall of text talking about their product.

I'm super bummed. These lights will be for sale eventually. They will be better in every way than your ZKWs, but the hassle of DIYing isn't worth it. ALs with ZKW lens swap is unequivocally the best option for your ZHP.

That really sucks that your having a hard time with them, however the centric rings are not needed with this retrofit. That's what the epoxy is for.


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[Hornung418]

Okay so what cutting method did you perform? I saw the picture...but what did you have to do to mount them flushly? They just look like they won't fit.

GS3 + TT4

[TomTomTuning]

Okay so what cutting method did you perform? I saw the picture...but what did you have to do to mount them flushly? They just look like they won't fit.

GS3 + TT4

I used a dermal to cut two different spot. One to clear the bi-xenon solenoid and the other to clear a bracket from the projector, then I had to go back and widen the 2nd cut so the shroud would sit flush and clear the bolts. Sounds like a lot but it was super easy and only tool a couple of minutes. Once I get back to my computer I'll try and illustrate the cuts in Photoshop and post the photo here.


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[Hornung418]

I will be buying a dremal then...thanks for helping me out with this!

GS3 + TT4

[330i ZHP]

nice writeup

[QC_ZHP]

How's everything holding up? Thinking about ordering the parts this week. My lights are brutal.

[Vas]

Curious as well since I am trying to decide which route to go with as well.

[QC_ZHP]

Parts came in Friday. Ordering bulbs and picking up a dremel this week and hopefully I can tackle this next weekend. I've resorted to using my fogs at night b/c my headlght output is so bad.

Should I swap the ZKW lenses in the new projectors or just use the ones provided?

[danewilson77]

ZKW lenses are the shit. Do the new lenses have a cutoff line?

[328ioc]

ZKW lenses are the shit. Do the new lenses have a cutoff line?

This. Definitely use the ZKW lenses.

Sent from my SCH-I545 using Tapatalk

[QC_ZHP]

ZKW lenses are the shit. Do the new lenses have a cutoff line?

No line on the new ones. Looks like I'll be swapping the lenses.

[danewilson77]

Ok. You don't want the line. I would just visually compare them.

Sent from my S4 > Mason, OH

[Dave1027]

My hid headlights are a little dim too. Could this burnt bowl thing be my problem? If so how about a simple and cheap fix. Would lining the bowls with something like this (http://www.amazon.com/Mirror-Flexible-Silver-Adhesive-CRAFTING/dp/B004XBRPL4) work?

[danewilson77]

My hid headlights are a little dim too. Could this burnt bowl thing be my problem? If so how about a simple and cheap fix. Would lining the bowls with something like this (http://www.amazon.com/Mirror-Flexible-Silver-Adhesive-CRAFTING/dp/B004XBRPL4) work?

Yes. If you have ZKW'S, it's most likely your problem.

No. There is no cheap fix.

Sent from my S4 > Mason, OH

[terraphantm]

Parts came in Friday. Ordering bulbs and picking up a dremel this week and hopefully I can tackle this next weekend. I've resorted to using my fogs at night b/c my headlght output is so bad.

Should I swap the ZKW lenses in the new projectors or just use the ones provided?
I'm pretty sure they come with ZKW replica lenses

[QC_ZHP]

I'm pretty sure they come with ZKW replica lenses

I've read of others swapping lenses. I'll just do a visual inspection and see which ones are in better shape.

[terraphantm]

I've read of others swapping lenses. I'll just do a visual inspection and see which ones are in better shape.

I've used both (on E46 AL projectors). Didn't really notice a difference in clarity or sharpness. My color band was actually a little better with the replicas. These aren't particularly complex lenses to make. Anyway, the kit comes with Evo-X R projectors. If they're not ZKW-R lenses, then they're likely a lens built specifically for that projector. Either way, they'd be optically clear, which is the important part.

[SC4ME]

Just ordered the TRS Retro-fit system (projectors & brackets only). Looks like a great project.

One question, why did you buy new shrouds instead of using the old ones (or are the old ones incompatible with these new projectors)?

I ask because the price just went from $15 to $40 for the shrouds. Thanks for the info!!

[QC_ZHP]

^There are 2 options for the shrouds. One is the value for $15, and the other is Premium for $40.


As soon as my Xenon bulbs & Angel Eyes come in, I'll be tackling this project as well. I've had the parts sitting in my room for a couple of weeks already.

[SC4ME]

I called TRS and they said I could use my OEM shrouds (with a little modification - but that is required anyway!)

[SC4ME]

This is my first DIY, so be warned... I know I missed a few photos, I'm terribly sorry.

I used the following tutorial for taking the headlights out and apart.

Here is where my DIY really begins:

Here is a very easy and cost solution for burnt ZKW projector bowls.

Items needed: $185.00 total (Free Shipping)
TRS Retro-Quick System (http://www.theretrofitsource.com/product_info.php?products_id=254) (Projectors and Brackets Only): $150.00
Value E46R Shrouds (http://www.theretrofitsource.com/product_info.php?products_id=131): $15.00
JB Weld Epoxy (http://www.theretrofitsource.com/product_info.php?products_id=31618): $5.00

This system uses Hella EvoX-R Projectors.
I also installed a set of 6000K bulbs.

Step 1 - Remove the four trox screws holding the projector bowl/lens to the bezel.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8753-Edit-1.jpg

Step 2 - Remove the lens from the shroud by pushing the two plastic tabs in, one on the left and one on the right.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8755-Edit-2.jpg

Here is everything taken apart, notice one of the holes does not go all the way through. The passenger side headlights requires that you drill that out, however the driver side is fine.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8757-Edit-3.jpg

Step 3 - Remove the rubber spacers and put them to the side, you're going to use them later. I used one of the screws to easily remove them.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8759-5.jpg

Step 4 - The existing holes are not big enough, so use a drill bit that's slightly larger then the supplied screws. I didn't pay attention to what size I used, sorry.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8761-6.jpg

At this point you can drill through that fourth hole (as previously mentioned).

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8763-8.jpg

Test fitting the screws, note you'll only be using 3.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8762-7.jpg

Step 5- Use a dermal to cut notches out of the bezel to allow for the high beam flicker module to fit.

Step 6- Put the rubber spacers back in, then the supplied black spacers and screws.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8764-Edit-9.jpg

Step 7 MISSING PHOTO - Mount the projector to the bezel and screw the 3 screws to the supplied nuts.

(since I forgot to take a photo of the projector mounted to the bezel, here is a detailed photo of what the projectors look like)
http://i9.photobucket.com/albums/a98/boostd240/6ypezyny-1.jpg

Step 8 - Use the dermal again to cut out notches to the top of the E46R shrouds.

(Old photo of a shroud TRS accidentally sent me, my notches were similar to this.)
http://i9.photobucket.com/albums/a98/boostd240/RUk0PwEh.jpg

Step 9- Mix your epoxy (I got clear epoxy from Amazon).

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8768-13.jpg

Step 9 - Apply the epoxy to the inside of the shroud and attach it to the bezel/projector. I used tape to hold it in place while it dried.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8767-12.jpg

Step 10 - Cut the OEM high beam flipper plug, and solder the new leads.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8765-11.jpg

Put it all back together and reinstall the headlights onto the car.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8774-15.jpg

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/885C9194-18.jpg

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/885C9184-16.jpg

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/885C9185-17.jpg

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/885C9200-19.jpg

A suggestion to all those who post DIY. Please take photos of completed assembly before installation. Especially when the kits come with zero instructions this is critical.

Thanks.

[QC_ZHP]

A suggestion to all those who post DIY. Please take photos of completed assembly before installation. Especially when the kits come with zero instructions this is critical.

Thanks.

Did you finish your retrofit?

[LivesNearCostco]

How would these three options rank in order of brightness?
--OEM ZKW with repaired projector bowl and OEM ZKW lens
--OEM AL with metal bowl and OEM AL lens
--Hella EvoX-R projectors with ZKW-R lens (I assume the quick kids include a ZKW-R lens)

I'm debating whether to get the E46 quick kit from TRS or the refinished ZKW refector bowls. My passenger side light is AL so it doesn't have burnt bowls but does have the lens with the line in it.

[QC_ZHP]

I've only had burnt ZKWs so I don't have a good comparison.

To take apart the headlight, the adjustment screws had to be set to move the headlight all the down and all the way to the left. I gave them a few spins back after putting them back together, but my cutoff line seems to be a bit low. My auto-leveling works fine, so would adjusting them up using the adjustment knobs raise the the cutoff at all or does the auto-level set the headlight level completely?

[danewilson77]

Where is TomTom?

[WOLFN8TR]

Where is TomTom?

He is MIA. Haven't seen him on the forums and I also sent him a text a month ago with no response. We were texting back and forth about the Eonon D5150 so I was in contact with him at one point. I will try again today. Kinda strange how he just disappeared.

[QC_ZHP]

He is MIA. Haven't seen him on the forums and I also sent him a text a month ago with no response. We were texting back and forth about the Eonon D5150 so I was in contact with him at one point. I will try again today. Kinda strange how he just disappeared.

+1. He joined around the same time I did and was putting a lot of work in then just stopped posting.

[TomTomTuning]

Sorry I've been MIA everyone. Things have been pretty hectic for me these past few months but I hope it calms down soon. I'll go back and answer any questions in this thread. :)


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[ELCID86]

Sorry I've been MIA everyone. Things have been pretty hectic for me these past few months but I hope it calms down soon. I'll go back and answer any questions in this thread. :)


Sent from my iPhone using Tapatalk 2

Glad you're back and ok.


Thumbs, iPhone, Tapatalk.

[Tnhl1989]

Hey Tom,

Were you still able to preserve the auto level with the retrofit? Is this the kit you use?

RETRO-QUIK: BMW E46 / ZKW (http://www.theretrofitsource.com/complete-retrofit-kits/morimoto-retro-quik-system-bmw-e46-zkw-lights-only.html)

Thinking about going this route or the AL route.

[TomTomTuning]

Hey Tom,

Were you still able to preserve the auto level with the retrofit? Is this the kit you use?

RETRO-QUIK: BMW E46 / ZKW (http://www.theretrofitsource.com/complete-retrofit-kits/morimoto-retro-quik-system-bmw-e46-zkw-lights-only.html)

Thinking about going this route or the AL route.
It should since you're only replacing the bowls/projectors. However, mine stopped working after the retrofit so I think I didn't plug the cables back in or popped a fuse. I haven't had time to investigate.


Sent from my iPhone using Tapatalk 2

[QC_ZHP]

Mine still works

[Nerius]

I just completed the TRS Retro-Quik retrofit as well. I don't have any pics of the before/after setup yet but I've included a few pics of my driver's side burnt (and rather crispy, I might add) bowl. I started with the passenger side which took me the better part of 3 hours. The driver's side took me 30-40 minutes tops. After I knew where all the clips were and how to push on them to get them to release without breaking the job got much easier!

http://i1099.photobucket.com/albums/g381/Nerius330/DSC_0514.jpg (http://s1099.photobucket.com/user/Nerius330/media/DSC_0514.jpg.html)

http://i1099.photobucket.com/albums/g381/Nerius330/DSC_0520.jpg (http://s1099.photobucket.com/user/Nerius330/media/DSC_0520.jpg.html)

[LivesNearCostco]

I bought this TRS Retro-Quick kit a few weeks ago but haven't had time to work on it yet. This DIY from Tom-Tom has been very helpful as the DIY instructions on the TRS site seem kind of incomplete. Only my left (driver's side) headlight is ZKW, so I will replace that one and compare brightness before deciding whether to retrofit the AL on the right side. TRS said the RetroQuick kit doesn't work with the AL projector.

[Tnhl1989]

Looking forward for more reviews before I hope on this track.

[TomTomTuning]

It's been 9 months and I've had no issues. I'm 100% satisfied with this retrofit!!! :) I highly recommend it.


Sent from my iPhone using Tapatalk 2

[midlandtech]

How am I just seeing this... I will be ordering soon.

taptalk + Note 3

[Hornung418]

LNC, the quick retro only works for the ZKWs. The ALs are superior as far as fit and finish goes. Honestly would just try to find an AL replacement for the ZKW side.

Sent from my GS3.

[Tnhl1989]

Yeah I'm considering just going the AL route. :)

[Hornung418]

Send a PM to jack.chris328. Hes got a million pairs. Even Asmod3us nay have some.

Sent from my GS3.

[LivesNearCostco]

Someone has a bunch of AL Bi-xenon headlights, or just the projectors? Are these for sedan or coupe?

I did the retrofit last night. Much better than my burnt ZKW and has sharper cutoff with more colors than the AL but is not as bright as the AL. HOWEVER it might be a bulb issue as the lights are different colors and IIRC both the bulbs are cheap D2S I bought from Khoalty more than 2 years ago, so maybe the left side bulb is failing. I will try to take pictures tonight of the light output and post them, along with "before" pictures with the burnt ZKW (with aluminum foil). Then later I will put in the new Morimoto bulbs from TRS.


Custom metal brackets in the E46 Retro-Quick fit pretty well
Didn't have to trim much of the housing to fit the solenoid of the new projectors
Wish they included instructions. Online instructions do not explain where/how to use the spacers. Without Tom-Tom's DIY, I wouldn't have known to re-use the two rubber spacers.
Had to trim top of shroud to clear two bolt heads and part of lens holder.
I cut off the two plastic clips on the shroud but in retrospect maybe should have left them there and used those as the epoxy points.
Once you epoxy on the shroud, will be difficult to take the projector apart again.
It appears polarity doesn't matter for the bi-xenon hi-beam shutter. I tested it both ways with 9V battery before installing.


Edit: pictures, all taken w/same camera, distance, ISO-400, 1/4th sec shutter, f3.5 aperture.

Left side only, burnt ZKW with foil
13937
Left side only, TRS EvoX-R projector (same bulb as burnt ZKW with foil)
13938

Both lights, before retrofit
13943
Both lights, after retrofit to left side
13941


Left only: TRS EvoX-R
13938[
Right only: AL OEM
13942

[LivesNearCostco]

If you compare the last two pics, that's why I say the OEM AL is slightly better than the EvoX-R projector, but the EvoX-R has a sharper cutoff and more interesting color on the cutoff line. Actually it seems at the top of the pattern near the cutoff they have about the same brighness, but the EvoX-R light drops off faster as you go downward than it does for the AL.

The AL has the lens with the horizontal line in the middle. I have the seamless ZKW lens leftover. I could take apart my AL light and swap in the ZKW lens to see if that gives it a better cutoff.

Edit: Forgot to mention, hi-beams have different patterns. On EvoX-R it's like a symmetrical mountain of light added on top of the pattern (see picture on the TRS site). For AL, don't remember, but quite different. Both the bi-xenon and auto-leveling functions continued to work after my retrofit.

[TWong1200]

It appears that TRS increased the price of this kit to $175. Boo! I will still be buying this kit.

Sent from my Nexus 5 using Tapatalk

[TomTomTuning]

Step 6- Put the rubber spacers back in, then the supplied black spacers and screws.

http://i9.photobucket.com/albums/a98/boostd240/E46%20TRS%20Retrofit/IMG_8764-Edit-9.jpg
So last night I notice a weird shadow projected onto the ground, it moved around as the car hit bumps and when I took turns.
I took the passenger headlight out to find that two of the black spacers (the top ones) had melted and was dangling inside the bowl, causing the shadow.
So I'm on my way to the hardware store hopping I can find metal spacer of similar size but because the shrouds are epoxied on, it's going to be a pain in the ass to work on.

I will notify TRS soon about this issue.

[flavo]

tomtom, do you have a suggestion to keep this from happening on future retrofits? I plan on ordering this kit very soon.

[TWong1200]

tomtom, do you have a suggestion to keep this from happening on future retrofits? I plan on ordering this kit very soon.
They are now made of aluminum from TRS

[slater]

They are now made of aluminum from TRS

yes, and TRS was kind enough to contact owners of this kit and send out the replacement spacers. i received mine a week or two ago. great customer service!

in retrospect, i don't remember using those spacers but used the OE ones. hmmm.

peter

[LivesNearCostco]

TRS contacted me too some weeks ago. I'm waiting for my replacement spacers but since I'm currently overseas, it's possible they're already at home waiting for me.

Of course my ZHP is still in the body shop so it's not like I can work on it... should be done by the time I get back.

Drove by a Costco in Taipei Monday... complete with tire shop. Didn't have time to visit--wondering what kinds of tires they sell there.

[flavo]

I think I read the whole thread and didnt see it mentioned anywhere. I just bought these and was about to pay through TRS website. The shipping brought it to $186 though and I only had $181 in my PP acount :eyetwitch
So i decided to check ebay. TRS is on ebay and they offer free shipping with a best off of $170 accepted. :thumbsup

[94jedi]

Guess what I'm doing lolhttp://tapatalk.imageshack.com/v2/14/11/02/c90f2a90eb944a1d54e6363a070b5d3d.jpg

[94jedi]

Pics of the projector mounted, as requested.
http://tapatalk.imageshack.com/v2/14/11/02/17a15c25dc93aea0a50e34041bf0c367.jpghttp://tapatalk.imageshack.com/v2/14/11/02/eded9befb71c1be52909b7e3bf6cd3e4.jpghttp://tapatalk.imageshack.com/v2/14/11/02/a6ea1c1397d270cde7700bfb531e3fc7.jpghttp://tapatalk.imageshack.com/v2/14/11/02/689f957e5923ccdfb99d5c4609a97a47.jpg

[Hornung418]

Looks great! Im gonna retrofit my e46 ALs into the 944 housings.

Sent from my GS3.

[94jedi]

Close up of the trimming necessary to make the projector clear the bezel. http://tapatalk.imageshack.com/v2/14/11/02/9493c43afd7ba0539fffc29b360d86dd.jpg

[94jedi]

Obligatory toast projector bowls pic. http://tapatalk.imageshack.com/v2/14/11/02/667a842fa34d8d3dcdb04e82da3e9e52.jpg

[94jedi]

Ok, I've had the trs retro quick kit on my car for a week now. It's a tremendous improvement for a decent price and moderate difficulty install. If you're on the fence, go for it. Definitely a worthwhile mod.

[jakksfor20]

They are now made of aluminum from TRS


yes, and TRS was kind enough to contact owners of this kit and send out the replacement spacers. i received mine a week or two ago. great customer service!

in retrospect, i don't remember using those spacers but used the OE ones. hmmm.

peter

Hmmmmm, I haven't been contacted. Maybe because I bought the kit in their store. They were unaware of the issue when I called them a few months back of the issue.

[LivesNearCostco]

I just got my aluminum spacers last Friday.

[94jedi]

For the record, my set came with the aluminum spacers.

[quikryptonite]

If anyone is looking to do a complete replacement with ALs, FCP Euro usually has a smashing sale for Black Friday weekend on an already competitive price for them:

FCP Euro AL Replacement (https://www.fcpeuro.com/products/bmw-headlight-assembly-xenon-left-325i-325xi-330i-330xi-63127165779)

[morraz3]

Just purchased this retrofit kit.. Do any of you, who completed this retrofit kit can be so kind and post pics of output range, and of the high beam. Also, how is the high beam activation, is it quick and swift like oem? Thanks in advance.

[94jedi]

Just purchased this retrofit kit.. Do any of you, who completed this retrofit kit can be so kind and post pics of output range, and of the high beam. Also, how is the high beam activation, is it quick and swift like oem? Thanks in advance.

HB is as good if not better, than OEM, IMHO. Output range is at least comparable, although I don't know what it was like because my car had burnt bowls when I bought it.

[2wenty]

Just bought a ZHP and discovered this is an issue. Looking for the best way to repair. Has no one tired to a place that chromes plastic? I would imagine that it will just burn off again though.

[danewilson77]

Just bought a ZHP and discovered this is an issue. Looking for the best way to repair. Has no one tired to a place that chromes plastic? I would imagine that it will just burn off again though.
You're on the right track in the burnt bowl refurbishment thread.

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[terraphantm]

Anyone do this recently? No matter what I do, I cannot get the screws to line up. I don't really want to dremel out the holes in the bracket since I might lose rotational alignment.

Kinda wishing I just bought a set of ALs

Edit:

Looks like I have to drill out the top two holes on the projector if I want them to fit.

[jakksfor20]

I would call TRS and ask. If I remember correctly I had to drill out some holes to make the screws fit, but it's been 2 years since I did the wife's ZHP.


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[danewilson77]

Anyone do this recently? No matter what I do, I cannot get the screws to line up. I don't really want to dremel out the holes in the bracket since I might lose rotational alignment.

Kinda wishing I just bought a set of ALs

Edit:

Looks like I have to drill out the top two holes on the projector if I want them to fit.
JW77 just did this last weekend. Did you get the Morimoto E46 kit?

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[terraphantm]

JW77 just did this last weekend. Did you get the Morimoto E46 kit?

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I got mine from theretrofitsource, which I believe are morimoto projectors.

[danewilson77]

I believe that's where he got his. If I remember correctly he had the same issue. He overcame this by slightly enlarging the holes. Also needed to modify the frame.

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[danewilson77]

I'll see if I can get him to chime in.

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[slater]

i used the TRS kit and did not have to drill any holes.

[justinwilson77]

Anyone do this recently? No matter what I do, I cannot get the screws to line up. I don't really want to dremel out the holes in the bracket since I might lose rotational alignment.

Kinda wishing I just bought a set of ALs

Edit:

Looks like I have to drill out the top two holes on the projector if I want them to fit.
Yea you have to drill them out. Not a whole lot though. I only drilled them out so the screws would slide in and out easily. The hole on the bottom I had to drill out more on the new projector because of how close the hole was to the metal bowl. They should fit fine as long as you drill them out and dremel a chunk out for that part on the bottom.

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[terraphantm]

Yea you have to drill them out. Not a whole lot though. I only drilled them out so the screws would slide in and out easily. The hole on the bottom I had to drill out more on the new projector because of how close the hole was to the metal bowl. They should fit fine as long as you drill them out and dremel a chunk out for that part on the bottom.

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Just to be clear, did you drill out the holes in the projector or the headlight frame? For me, it's looking like I have to slightly drill out the holes in the projector.

[justinwilson77]

Just to be clear, did you drill out the holes in the projector or the headlight frame? For me, it's looking like I have to slightly drill out the holes in the projector.

Just to be clear, you have to drill out all of the holes in the headlight frame as noted in Step 4 of this DIY. Also, I found that the lower hole on the actual projectror did not have enough space for the hex-head bolt to sit properly and thus, I had to drill out that hole as well. That hole was not in the metal part of the projector lens, it was the one in the black material, the piss poor picture below shows where that's at. http://images.tapatalk-cdn.com/15/12/23/54fa7c8b75296ca34cf8f2fbceb0d113.jpg

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[terraphantm]

So I got my projectors in - ended up widening the holes in the projector slightly and used some washers just in case. Seems to be level and the projector fits well. Projector does seem to sit a little farther back than stock since the shroud bottoms out before fully enclosing the lense. Not super noticeable. Have the shroud held in with friction for now; I'll epoxy it after I'm sure there are no adjustments necessary.

[terraphantm]

Hmm. Drove around a bit with the new projectors... And I don't really like them. They're better than the burned ZKWs, but my M3's AL headlamps seem to put out more usable light. I think I'm going to hunt for a set of ALs

[rguti153]

These are not the fxr projectors are they ?

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[anandoc]

These are not the fxr projectors are they ?

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Nope. The TRS retro-quick system uses the Hella EvoX-R projectors.

[az3579]

Nope. The TRS retro-quick system uses the Hella EvoX-R projectors.
Does it vary? Though I saw a Retro-Quick kit that used a Mini projector...

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[terraphantm]

Does it vary? Though I saw a Retro-Quick kit that used a Mini projector...

Sent from my LG V10 on Tapatalk

Maybe halogens or just other cars in general. For the ZKW xenons, the kit has always been the EvoX-Rs

[rguti153]

That blows cause I know the fxr r really good , n I was surprise to hear u didn't like them , but I was thinking they were the fxr projectors .

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[az3579]

That blows cause I know the fxr r really good , n I was surprise to hear u didn't like them , but I was thinking they were the fxr projectors .

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I don't think he has FX-R's...

My FX-R v1.0's are a bit better than the M3 AL projectors I had before. They appear to me to have a sharper cutoff and they have a much wider beam pattern, which I really like. FX-R's are phenomenal, especially if you get the latest and greatest version (3).

[anandoc]

+1

I have the FX-R 3.0s and I have not seen a sharper cut-off in another car. I believe the bulbs that I have are the 11 year old original ones which came with the car. I can only imagine how much better the light output would be if I put in new Osram CBIs.

[terraphantm]

Don't get me wrong, the cutoff is ridiculously sharp on these (almost too sharp honestly), and the beam width is probably a bit better than the ALs. And the highbeams are spectacular. But the low beams seem lackluster. The ALs feel better for high speed driving to me.

[jakksfor20]

Don't get me wrong, the cutoff is ridiculously sharp on these (almost too sharp honestly), and the beam width is probably a bit better than the ALs. And the highbeams are spectacular. But the low beams seem lackluster. The ALs feel better for high speed driving to me.

That is the problem my wife has with ours. She likes driving my car(323ci) better at night because she says the beam is scattered more and there is not a sharp cut off. I'm half tempted to trade ours for a set of AL's or just pick up a set.


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[terraphantm]

That is the problem my wife has with ours. She likes driving my car(323ci) better at night because she says the beam is scattered more and there is not a sharp cut off. I'm half tempted to trade ours for a set of AL's or just pick up a set.


Sent from my iPhone using Tapatalk

Yeah that's probably what I'm going to do. Hell, since my M3 is going to be parked for the winter, maybe I'll just steal the ALs out of that for now.

Another thought I had was using the Hella "E55" projectors rather than the EvoX-Rs. They appear to be dimensionally identical to me, but since they're OEM projectors, they might work better. My dad's E60 has the D1S variants of the E55 projectors, and they seem to be nicer for actual driving (even if the EvoX-Rs photograph better)

[egiles14]

I just wanted to say a big 'Thank you' to Tom and others who have greatly contributed to this thread. I spent most of the day installing the projector retrofit kit from The Retrofit Source, as well as clearing up the cloudy headlight lenses using Meguiar's Perfect Clarity 2-step kit. This write-up was much appreciated, as TRS doesn't provide any instructions. The light output using the factory xenon bulbs is excellent, and literally a night and day difference from the burned ZKW projector bowls.

[theothersawyer]

I will be doing this one pretty soon!

[swchang]

I wasn't sure if I should post in this thread or start my own. Apologies if I chose incorrectly.

I recently brought my car to a well-regarded indy shop in my area. The shop owner, who seems to know what he's doing, said he could not install the retrofit kit that people here are recommending. I bought this (https://www.theretrofitsource.com/complete-retrofit-kits/application-specific/morimoto-retro-quik-system-bmw-e46-zkw-lights-only.html#.V6UIdvkrKM9) and even gave him the link to this thread. Regardless, he said he had a few problems:

1) He could slide the silver plastic covering (not sure of the proper name) over the projector, but it wouldn't latch on or fasten anywhere. It would just slide back off.
2) He said the entire assembly was too long.
3) The wiring pins were incorrect.
4) He said to make things fit he would have had to do a substantial amount of Dremeling.

He thinks I got the wrong parts. Any thoughts or suggestions?

Thanks in advance.

[terraphantm]

1) He could slide the silver plastic covering (not sure of the proper name) over the projector, but it wouldn't latch on or fasten anywhere. It would just slide back off.
2) He said the entire assembly was too long.
3) The wiring pins were incorrect.
4) He said to make things fit he would have had to do a substantial amount of Dremeling.

He thinks I got the wrong parts. Any thoughts or suggestions?

Thanks in advance.

1) Yeah they don't latch on. I just pressed mine on really hard and they're holding so far. Otherwise they can be glued on
2) The assembly is longer but still fits
3) The wires are for the bixenon shutter. Just cut and splice them into the stock connection. Polarity doesn't matter.
4) A fair bit of dremeling is required.

[Sockethead]

I understand you shop's paranoia of modifying the housing to the point of no return... A little scary doing that to units that are over 1k a piece...

[i_b_bass]

FYI, if anybody orders the E46 repair kit directly from The Retrofit Source, the kit now comes with the Morimoto Mini DS2 4.0 projectors. The install is pretty much the same, but it's my understanding that the ZKW adapter bracket is mounted differently than the FX-Rs. The photo below is how the ZKW adapter fits onto the Mini DS2 4.0 projectors.31116

[isherwood]

Thread necromancy warning.

I'm going to be replacing the twice-burnt ZKW Xenons on my '04 sedan. The Retro-Quik product page (https://www.theretrofitsource.com/morimoto-retroquik-bmw-e46-zkw-repair-CRK-RQ-E46) has virtually no information on it. I don't know how they sell anything.

Questions...

Do the kits come with bulbs, or do they default to none assuming I already have bulbs?

Do I need the shrouds mentioned in the original post here? The kit seems to have them.

Is this even the right solution for a bi-Xenon stock headlight replacement?

Thanks. It's been difficult to determine what info in this thread is still accurate and relevant. 'Preciate any updates. I'll be sure to contribute what I learn as I go. Might even do a full updated how-to.

[rguti153]

Thread necromancy warning.

I'm going to be replacing the twice-burnt ZKW Xenons on my '04 sedan. The Retro-Quik product page (https://www.theretrofitsource.com/morimoto-retroquik-bmw-e46-zkw-repair-CRK-RQ-E46) has virtually no information on it. I don't know how they sell anything.

Questions...

Do the kits come with bulbs, or do they default to none assuming I already have bulbs?

Do I need the shrouds mentioned in the original post here? The kit seems to have them.

Is this even the right solution for a bi-Xenon stock headlight replacement?

Thanks. It's been difficult to determine what info in this thread is still accurate and relevant. 'Preciate any updates. I'll be sure to contribute what I learn as I go. Might even do a full updated how-to.It does not come with bulbs, u can used ur original bulbs but you might as well buy new ones, I chose 5k color ones . I reused the original shrouds that came from the zkw headlights . This is not an easy plug and play set up . There is some modification you have to do to the bracket shrouds . But overall light output is superb [emoji108] . Would I do it again yes I will . Good luck

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[holyc0w]

Thread necromancy warning.

I'm going to be replacing the twice-burnt ZKW Xenons on my '04 sedan. The Retro-Quik product page (https://www.theretrofitsource.com/morimoto-retroquik-bmw-e46-zkw-repair-CRK-RQ-E46) has virtually no information on it. I don't know how they sell anything.

Questions...

Do the kits come with bulbs, or do they default to none assuming I already have bulbs?

Do I need the shrouds mentioned in the original post here? The kit seems to have them.

Is this even the right solution for a bi-Xenon stock headlight replacement?

Thanks. It's been difficult to determine what info in this thread is still accurate and relevant. 'Preciate any updates. I'll be sure to contribute what I learn as I go. Might even do a full updated how-to.

I don't believe it comes with bulbs unless you add the optional bulbs. Based on the bottom left on that page, it includes the projectors and the brackets.

There is a DIY here for the Mini D2S 4.0, but I believe this was done without the bracket hardware:
http://www.zhpmafia.com/forums/showthread.php?19877-Yet-another-projector-retrofit-tutorial-ZKW-gt-Morimoto-Mini-D2S-4-0

[isherwood]

I'm going to have to pull my foot out of my mouth. Apparently the page wasn't fully loaded when I looked the first time, and all that helpful info down below wasn't showing for me. That sure clears some things up.

Thanks for the replies.