ZKW to AL Swap: Mounting Bracket?

[Crickett]

So I bought a good-condition used AL assembly to do a wholesale replacement of my burnt-bowl ZKW passenger-side (right-side) headlight, figuring it should be a straightforward direct-fit replacement.

After removing the ZKW assembly, I noticed the AL headlight wasn't fitting quite right & wasn't lining up correctly with the mounting screw locations. After a bit of investigation & comparison to my driver-side (left) headlight (already an AL unit), I noticed the lower mounting bracket was different.

(Talking about part #10 here, P/N 63-12-8-380-188)
http://static.bmwfans.info/images/epc/MTUyOTYzX3A=.png

Everywhere I looked only listed that single P/N for that bracket, with no notes to indicate that there is any difference in fitment or application for ZKW or AL units. BUT, my LH AL headlight's bracket looks like this:

http://www.pelicanparts.com/cgi-bin/smart/imgdsply.cgi?pn=63128380188-M89

Whereas my RH ZKW bracket looked like this:

http://www.pelicanparts.com/cgi-bin/smart/imgdsply.cgi?pn=63128380187-M89

(These pics are actually of a right-side "AL" & a left-side "ZKW", so just mirror them in your head. Additionally, my fitment issue isn't a right-vs-left as I've seen both left & right brackets of both types.)

The major difference I noted is a "notch" on the outside edge of the "AL" bracket where the "ZKW" bracket has a solid "shelf" down the entire length. Said notch appeared to be necessary for the AL light to sit flush against the bracket as it has more modules on the bottom of the assembly (compared to the ZKW). So I broke out the power tools & cut a matching notch into my "ZKW" bracket to allow the bottom of the AL to clear the bracket & sit flush.

After modifying the bracket I was able to line up all four mounting holes & get the AL "installed", but the bottom edge of the headlight still doesn't sit correctly in relation to the bumper: there's a significant gap between the lower headlight trim piece & the bumper when everything's installed. It's almost as if the whole assembly is angled up too much, or that the back end of this lower bracket isn't holding the headlight up well enough.

Has anyone run into issues like this or know of a fix / reason it's not sitting correctly? A new, notched bracket is ~$50, so it wouldn't be a huge issue if that the solution, but all of the research I've done so far seems to indicate that the brackets should be the same regardless of AL or ZKW. :dunno

[nike001]

Sorry, I didn't really read the whole post.. but you do need #10 for the AL headlight to correctly mount in

[derbo]

You can trim #10


Couple notes: ZKW Lower mounting bracket is different than the AL lower mounting bracket. Nothing a dremel couldn't fix. The red portion is not present on the AL mounting bracket but it is there on the ZKW.

http://img.skitch.com/20111227-menne4nrdqi4qwc4w9rmua6fu1.png



Those are the notes I made when I put my AL headlights in.

[JupiterBMW]

Yes, I trimmed the bracket as well, as you mentioned and as Derek showed with the red markings... In addition, on the underside of the headlight I also trimmed off the 'slot' that the brackets slide into on the leading edge. This allows for super fast removal, and also allowed them to sit perfectly. It took me a while to figure out exactly where it was hitting, but if you install it a bit, see where it hits, take it out, trim it, then reinstall, etc etc... It will work.

If you flip over your headlight and take a pic of the underside, I can PS it and show you where I trimmed...

Also, for the sake of future removal, I didn't reinstall that pain in the ass screw on the inner bottom. The one closest to the kidneys... F that screw, its a pain to get in and out and the lights are PLENTY secure with just the 3 other bolts.

[Crickett]

[ . . . ] In addition, on the underside of the headlight I also trimmed off the 'slot' that the brackets slide into on the leading edge. [ . . . ]

Thank you!! That's what I missed, I didn't notice that there were slots! So after a quick adjustment, my light now sits mounted correctly!

Now, does anyone know of an easy way to remove one of the aiming adjustment knobs? My eBay AL is missing the horizontal adjustment knob & I already broke off one of my ZKW's. :facepalm

[JupiterBMW]

Hmm, you're on your own on that one... I will say this, go easy on them! :rofl

[quikryptonite]

So, are these the right brackets for the AL's?

Right Bracket (http://www.ecstuning.com/Search/63128380188/ES173222/)

Left Bracket (http://www.ecstuning.com/Search/63128380187/ES173221/)

Do you just remove the old ZKW brackets and screw these ones in?

[Crickett]

So, are these the right brackets for the AL's?

Right Bracket (http://www.ecstuning.com/Search/63128380188/ES173222/)

Left Bracket (http://www.ecstuning.com/Search/63128380187/ES173221/)

Do you just remove the old ZKW brackets and screw these ones in?

Affirmative on both counts: those are the correct brackets for ALs & they are a direct swap with the ZKW brackets. That said, the ZKW brackets are identical except for the spot marked by derbo a few posts up. The extra plastic on the ZKW brackets is easily removed (via Dremel or similar) to make them work with ALs.

[derbo]

Its better to just cut and save the extra cash for something else down the line :)

[jack.chris328]

Thank you!! That's what I missed, I didn't notice that there were slots! So after a quick adjustment, my light now sits mounted correctly!

Now, does anyone know of an easy way to remove one of the aiming adjustment knobs? My eBay AL is missing the horizontal adjustment knob & I already broke off one of my ZKW's. :facepalm

Where are you trying to remove it from? The ZKW light? The ZKW adjusting knob won't work an a AL light. It is longer. If you need one PM me. I am sure I have one.

[quikryptonite]

If anyone needs a mounting bracket let me know, I'll make you a good deal.

[trancenation]

From my understanding, if I were to Install AL Brand Headlights with AL Brackets, I wouldn't have to alter the brackets as they would be direct plug and play?

[danewilson77]

On a coupe, yes I believe you would be fine. On a sedan, the brackets would need altered as ZKW's were what came out of it. Someone back me up here.

[Avetiso]

On a coupe, yes I believe you would be fine. On a sedan, the brackets would need altered as ZKW's were what came out of it. Someone back me up here.

Depending if it's ZCW...

Sent from a junkyard via GS4.

[trancenation]

My car is a sedan that has zkws so by putting AL headlights in with AL brackets I would need to alter the AL brackets. Are the Zkw brackets suitable for use on the AL headlight without modifications?

[danewilson77]

My car is a sedan that has zkws so by putting AL headlights in with AL brackets I would need to alter the AL brackets. Are the Zkw brackets suitable for use on the AL headlight without modifications?

No.

Sent from my Samsung Galaxy S4

[quikryptonite]

Are you talking about part No. 10:

http://realoem.com/bmw/diagrams/l/e/307.png

Dane is right. I replaced one of my ZKW's with the AL and I needed a new mounting bracket (no. 10) as the AL assembly wouldn't attach to the ZKW bracket. The AL assembly I bought from FCP came with one. I had to wiggle it around a little bit to get the trim piece to sit properly.

[danewilson77]

Just cut it with a Dremel.

Sent from my Samsung Galaxy S4

[trancenation]

Got it!

[scooby24]

Has anyone attempted the TRS retroquick system for the ZKW's yet? Seems like that would be more popular instead of getting used lights and having to swap out brackets.

http://www.theretrofitsource.com/product_info.php?products_id=254

[Avetiso]

Has anyone attempted the TRS retroquick system for the ZKW's yet? Seems like that would be more popular instead of getting used lights and having to swap out brackets.

http://www.theretrofitsource.com/product_info.php?products_id=254
Tom just did this, I think. He wrote an excellent DIY for it, as well.

[scooby24]

Tom just did this, I think. He wrote an excellent DIY for it, as well.

Ha, I just saw his thread after I posted it. Hmmm, not quite plug and play like they advertise. Still....I did the FX-R 3.0 retrofit and that sucked, so I would have much rather dealt with the minor modification of the retro-quick setup.

[danewilson77]

Got it!

You've seen my thread, correct?

Sent from my Samsung Galaxy S4

[danewilson77]

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketdriversidebefore1.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/ZKWlightbracketdriversidebefore1.jpg.html)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketdriversideafter.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/ZKWlightbracketdriversideafter.jpg.html)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketpassengersidebefore.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/ZKWlightbracketpassengersidebefore.jpg.html)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/IMAG2189.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/IMAG2189.jpg.html)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWALHeadlighthousingundersidecomparison.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/ZKWALHeadlighthousingundersidecomparison.jpg.html)

Sent from my Samsung Galaxy S4

[trancenation]

I haven't seen it yet. Did you have to do something different because of the headlight washers? I have zcw as well.

[danewilson77]

I haven't seen it yet. Did you have to do something different because of the headlight washers? I have zcw as well.

You see the pics correct?

Sent from my Samsung Galaxy S4

[trancenation]

I did my AL Retrofit today and luckily my AL units came with the lower brackets that I could use for the car. Thanks Dane for the clear pictures of what needed to be done in terms of modification.

[danewilson77]

I did my AL Retrofit today and luckily my AL units came with the lower brackets that I could use for the car. Thanks Dane for the clear pictures of what needed to be done in terms of modification.

You bet Amigo.

Sent from my Samsung Galaxy S4

[JupiterBMW]

FWIW to anyone else doing this. I have a brand new set of AL brackets, no need for them. Pay shipping and they're yours.

[Hornung418]

FWIW to anyone else doing this. I have a brand new set of AL brackets, no need for them. Pay shipping and they're yours.

I'll take em.

GS3 + TT4

[STREETFIGHTER50]

Bumping this up again. I just got a set of AL headlights recently. Can someone repost the pictures of what needs to be trimmed from the ZKW brackets?

[Hornung418]

Bumping this up again. I just got a set of AL headlights recently. Can someone repost the pictures of what needs to be trimmed from the ZKW brackets?Pull the bracket and put it on the headlight. You'll see where the clearance becomes an issue around the ignitor housing. There are definitely some pics on the googler.

Sent from my Nexus 6P using Tapatalk

[cakM3]

Bumping this up again. I just got a set of AL headlights recently. Can someone repost the pictures of what needs to be trimmed from the ZKW brackets?

I found it easier just to swap in the ZKW lens into the AL headlight assembly. Both the Bosch and ZKW lens are the same size so it was just a simple swap and use the AL headlight assembly rather than try making the AL bowls fit into the ZKW assembly. I have done this to both my ZHP and M3 :thumbsup

[az3579]

I found it easier just to swap in the ZKW lens into the AL headlight assembly. Both the Bosch and ZKW lens are the same size so it was just a simple swap and use the AL headlight assembly rather than try making the AL bowls fit into the ZKW assembly. I have done this to both my ZHP and M3 :thumbsup
He can't mount his headlight without modifying the bracket, so he has to go through this anyway.

Sent from my Pixel using Tapatalk

[joeybananaz18]

If anyone has a pair of AL brackets lying around that they're not going to use, please let me know. Im doing the swap to AL headlights and I don't believe my lights came with brackets. And I suck with a dremel.

[az3579]

If anyone has a pair of AL brackets lying around that they're not going to use, please let me know. Im doing the swap to AL headlights and I don't believe my lights came with brackets. And I suck with a dremel.You're in NY, right? How bout I must make a road trip and Dremel it for you? Save you the effort. [emoji4]

Sent from my Pixel using Tapatalk

[joeybananaz18]

You're in NY, right? How bout I must make a road trip and Dremel it for you? Save you the effort. [emoji4]

Sent from my Pixel using Tapatalk

Im just a few minutes away from the danbury boarder. Careful I might take you up on that offer. The wife and I are still getting settled in the new house but I wouldn't mind hosting a mafia BBQ one day.

[az3579]

Careful I might take you up on that offer.

I don't offer unless I'm serious. Hit me up when you're ready. :thumbsup

[BMWCurves]

I don't offer unless I'm serious. Hit me up when you're ready. :thumbsup

This is why this place is great.

[joeybananaz18]

This is why this place is great.

Beat me to it. I love this place.


Sent from my iPhone using Tapatalk

[stephenkirsh]

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketdriversidebefore1.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/ZKWlightbracketdriversidebefore1.jpg.html)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketdriversideafter.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/ZKWlightbracketdriversideafter.jpg.html)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketpassengersidebefore.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/ZKWlightbracketpassengersidebefore.jpg.html)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/IMAG2189.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/IMAG2189.jpg.html)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWALHeadlighthousingundersidecomparison.jpg (http://s1015.photobucket.com/user/nicee46/media/Maintenance%20and%20Misc/ZKWALHeadlighthousingundersidecomparison.jpg.html)

Sent from my Samsung Galaxy S4

Bumping the thread.

I just did this on my ZSP I just bought. Thanks for posting the pics.

[az3579]

Bumping the thread.

I just did this on my ZSP I just bought. Thanks for posting the pics.

Did the ZSP originally have halogens or ZKW Xenons? I've never seen ZKW Xenons on a non-ZHP before, so I'm trying to figure out if my theory is correct.

[stephenkirsh]

Did the ZSP originally have halogens or ZKW Xenons? I've never seen ZKW Xenons on a non-ZHP before, so I'm trying to figure out if my theory is correct.

It had zkw xenons from factory.

I’m gunna try and rebuild them and put them on my halogen ZHP. Has anybody done that?

[stephenkirsh]

Zkw on top.

34140

[dpark]

Just cut it with a Dremel.

Sent from my Samsung Galaxy S4

Well, I guess I made the right choice. I just posted a thread about my effort swapping a MM/AL assembly with my ZKW and I eventually figured out I needed to dremel out the ZKW mounting bracket that went around the headlight washers.

Glad I made the right decision.

However (and I have not gotten to the end of this thread) I still had a "gap" on the outside part of the MM/AL assembly there it abuts the turn signal. I could not figure out how to close that gap.