DIY-Bi-Xenon headlight conversion - Really can be done- $300

Just wanted to share my newest project. Converting my headlights to Bi-Xenon lights. Pics can't do the look justice. Really improved my night driving vision and gave the headlights a modern look. Well worth the price & effort. EDIT: Here are my instructions. I'll post pics later tonight. 1. Use tool (5mm) to remove headlight assemblies from fenders 2. Remove screws and signal triangle Remove all bulbs, tape openings closed 3. Use heat gun to soften sealant and separate lens from assembly a. Start from top of lens using screwdriver or wide blade tool b. Use wedges to keep gap open c. Do melt plastic with too much heat- monitor heat with digital thermometer d. Wear gloves & old clothes– everything with get black sealant on it 4. Remove 2 screws and slide out clear bezel 5. Remove inside screws and remove reflector 6. Use file to open socket opening so you can fit in new Xenon reflector housing 7. Use grinder to remove the tab in reflector 8. Install Xenon reflector assemble into Porsche reflector, and tighten 9. Reassemble the reflector and bezel back into the light housing a. Be careful not to over tighten screws b. Make sure everything is back in place 10. Insert Xenon bulb into Xenon reflector ( after cleaning bulb) 11. Attach wiring 12. Slide headlight assembly back in to fender so you can rotate the reflector so that the beam is perfectly horizontal. You will set height later on. 13. Remove headlight assemblies, disconnect wiring 14. Reaffix the lens to the headlight assembly with sealant (I used urethane windshield adhesive, but there is headlight lens sealant available) 15. Reconnect wiring and connect high beam connections. 16. Pack wiring and ballasts into the headlight assembly, install rear covers 17. Install headlight assemblies back into the fenders 18. Confirm that they work. 19. Use hex tool to align height of low beams

hey Jim, nice project but I am hoping for more details

Yes, I'll include all the gory details & pics later, but I left camera at home, but I snapped this pic with new EVO 3D as I left the house. Removing the cover lens is real fun! Luckily I had an extra headlight to practice on before I tackled the ones from my car. You have to completely disassemble the headlights in order to install the lights. BUT the difference in illumination is fantastic. Plus a more modern look at 1/10th the cost of Litronics AND the highbeams are Xenon, Litronics aren't.

Need details as soon as possible. This is a mod I am very interested in.

I am interested also.

Lots of progress last night, but ran out of time before completion. Here is a pic while I was checking the alignment, the pic of the front of the car doesn't capture the look of the lights accurately, I'll retake it with different exposure so you can see the Xenon lenses as they actually look. Also included a pic of the Bi-Xenon parts that I bought. I'll start to organize pics and instructions. What a great improvement in LIGHTING!!!! And gave the car's lights a more modern look even when they are off.

Very cool! This will be a great mod.

Looks great! I'll be following this one for sure. Did you have an amber turn signal section in your covers and amber triangles along the bottom to start with or are you somehow changing them to clear in addition to the Xenon? I had always thought we were stuck with the amber bottom section since its a one piece lense cover.

Nice job! And what a great contribution to the community. Looking forward to seeing them in person.

Have you ever considered selling these?

If you buy the Bosch parts, it's an easy job to do. Even wiring in the leveling controller is simple and takes less time that one might think. Did the conversion on a customers car, lights, controller and install was less than $3k.

[QUOTE=SeanR;8692132]If you buy the Bosch parts, it's an easy job to do. Even wiring in the leveling controller is simple and takes less time that one might think. Did the conversion on a customers car, lights, controller and install was less than $3k. QUOTE] Hmmmm $3,000 vs <$300. Oh yeah, the Litronic is not Bi-Xenon. The early Litronic used Halogen brights. This wiring uses the H1 light socket that plugged into your Halogen bulb.

Quotes source post: 8692119

Let's talk- Send me a mssg. thx

Jim, any updates or instructions on the mod? I would like to attempt. Thx

Quotes source post: 8721400

DITTO

Yeah, some DYI instructions will be great

wait, im confused... :-) did you take a standard set and put the projector lenses in, or just put hid bulbs in them?

how can you take out the cover lens ?? thank!!

Quotes source posts: 8722556, 8692119, 8691223, 8721400, 8727095

I have written instructions and will post pics on the original 1st post. I figure that makes more sense that nesting it in the middle of the post. I installed a complete BiXenon assembly with reflectors with Hi/Lo shutter. Inserting just a Xenon bulb is a poor idea. the reflector and les wasn't made for it. I might do a batch if interest I do have the amber signals but painted the cover with translucent automotive paint. I did check with Bosch to see if i could get new lenses, but no luck. Only solution would be to source from overseas. But would need sufficient $$ or orders. I would think there would be some demand for new complete clear lenses. ....still investigating See my first post. I am updating... See first post. You will spend the most time removing the lenses. And it is messy and you want tot make sure not to melt the plastic with too much heat. I practiced on an extra headlight assembly, before I tackled my real set, and I swallowed real hard just before I started up the heat gun. You can also put the assembly into the oven, but I decided not to irritate the wife with a smelly house, and the heat gun method had worked on the test assembly.

Is this a kit, or did you dream this thing up? Really nice!

thank you for your answer! but i want make sure, you only use heat gun take the lens out right? or some more tools? thanks

Quotes source post: 8729827

You use the heat gun to melt the sealant. It will soften just over 200F. I used a infrared themometer to make sure it didn't get to hot. I used pry type tools to seperate the cover from the assembly. I would of taken pics as I did this to the 3 headlights that I worked on, but it was so messy that the camera would of been black and gooey, plus once you start you do not want to stop. You want to start at the top and then work down the sides, alternating back and forth.

thanks so much 15psi

Quotes source post: 8729683

I think this is the first 996 conversion. I bought the parts from http://www.theretrofitsource.com . (no affliation) They are very helpful and knowledgeable. You want 35w, Mini reflector, H1. Let me know if you want more info. I bought on a 'group buy' that was on a Mazda forum. I could set one up. Good source for BiXenon installs and general info http://www.hidplanet.com/forums/

Jim, Which model of retrofit kit did you purchase?

I know this thread dates back 2+ years ago, but I'm planning on doing the same, and I sent you an email 15psi asking for more information. I'm new to Porsche, as it's my father's car, but his 996 C2 headlights have the "burnt" plastic from the light bulbs, and this would be a great alternative instead of buying a new set of headlights. Maybe someone can confirm, the low-beam and high-beam are separated in the middle? I can't make out if he only used the bi-xenon projectors and a "high-beam" bulb or simply the projectors. Thanks, JP

Quotes source post: 10695675

ditto that. my lenses and such are showing their age. Also, since it was two years ago, would be a good status check and did any one else follow up and attempt? Looks great. Sent from my iPad using Rennlist

Have a look at: http://986forum.com/forums/diy-proje...-finish-3.html Identical headlight. Page 3 and 4 are filled with pictures.

Fully customized projectors avails for the 996 as well. Pretty cool kit

^^^^ Impressive kit. Very well done.

Nine8Six - your kit is great. How would I go about contacting you for more information?

Quotes source post: 10868805

Same name can be found over at www.986forums.com . You can either message him there or shoot me a pm and I'm sure he won't mind if I give you his contact email.

Joseph, David, apologies to both of you for the delay. Perhaps I should subscribe to the thread I post into :/ Anyway, that's done now. I've also subscribed to your forum so I can receive and send PMs. This didn't seem to work too well with the free account. Joseph, you can contact me by PM or by email. My addy is Frederic AT multilogik DOT com You guys know if this basic account membership allows me to publish the price and details of the GT bi-xenon projector kit that I recently designed? It is a brilliant kit shaving off minimum 10 years off fellow's Porsche 9x6. Not mentioning about far better visibility/optics. I'd really like to make this one available (with reduced price for forum members) but have a thread on its own for it. But all depending on the rules. Cant find anything related to this other than reading I am allowed to two commercial post per month or similar. You guys better informed than I am maybe? David, thanks for passing over my contact details. Much appreciated!

Nine8Six, thanks for posting your work here! Looks nice, I sent you an email. cheers, Herb

Thanks Herbert, email received/replied. Copy/paste the email I've replied in case other members needs to have additional details: >>>> Thanks for your email! Agree with you those would be perfect for your 996. They shaved off about 10 years on my 97 boxster so I'm expecting the same effect on yours. They do look great or somehow factory, not to mention the added visibility you will be getting. However, DIY complexity is 'medium'. All the hard work goes into removing the lens off the headlight (oven a few times, patience etc). The rest is pretty elementary and quite unchallenging-ly boring frankly. Other than enlarging the H7 bulb socket size by 1.5mm with a dremel sand-wheel, there are no other modifications required to the headlight. HID Ballasts connects to the H7 low beam bulb connector. Xenon solenoid connects to the H7 high beam bulb connector. That's it really. Now the question is to yourself; are you cool with doing them? If so, then let's crack on.... I'll be happy to give it all I got for your kit. As for the price, the damage is $355 shipped using Express Post w/ tracking number. Includes: 2x Silver shrouds (w/ "Porsche Motorsports Optics") or you can customize the script/wordings 2x Anodized black projector skirts 2x MH1 Projectors & lens 2x 35w CANBUS HID ballasts 2x H1 HID bulbs (you chose your temp e.g. 4,3k is factory white, 6k is with a 5% tint of blue) 2x Hardware kit: spacer kit, dremel wheels and two Porsche emblems * Return and refund accepted shall you decide to not install the kit. I normally send a PayPal "Request for Money" to your email using the "For Goods" option and list all the above in the invoice. That way the buyer feels comfortable and covered by the PayPal Buyer Protection Scheme. If you are all good with that, just send me your PP addy and I'll get a kit done just for you in less than a week mate. Any questions just ask anytime Fred Latest work for a Zanzibar red car: In silver (factory style) with the other bits incl in the kit: Final product:

Might be worth mentioning I do these as a "hobby" (not commercial). I did my own headlights and was offering other fellow Pcar owners the same.... in case like myself, one had enough of the old fugly halogen style shiners

Fred does excellent work and that's surely one heck of a hobby he's got going which definitely shows the passion he has for these cars first and foremost. Great job!

sent you a PM Nine8Six

Thanks x100 Joseph, replied sent [@alpine003] David - same goes to you Fred

I've ordered a kit from Fred (Nine8Six) as well. One question that comes to mind is what do I use to glue the lens and body back together once I've opened it up to install the light?

Quotes source post: 10888302

Any high quality Black RTV Silicone will do. I've had good success with Permatex brand in the past which can be found off the shelf.

Nice work !

My kit from Fred arrived last night. So today I'm going to start to take apart the enclosures. I'll try to remember to take photos of the entire process of installing the new lights.

Quotes source post: 10940211

Will be interested to see these in person.

I managed to remove the cover over the light assembly. But I'm stuck at removing the inside cover over the bulb. Anyone have any advice? ForumRunner_20131129_181406.png

Nick - sorry for the late appearance. I am enjoying replying all of your emails within hours that they are sent to me. Zero worries there, but missed this post. Regardless, advice has been given RE your reflector shield removal the very same day you posted above. Just showing up here just so nobody thinks I've vanished from the world Nick, and others who also got a kit, you have my email addy and mobile phone number (GMT+08) if anything urgent that you are stuck with! I'm also pretty active on the other forum. I'll try to get a thread going standalone on here so you guys can post tips and tricks with pics soon.

Quotes source post: 10941251

So how did you do it? I will be doing this very soon. I already have my kit from Fred.

I did that just the day before yesterday... there are 3 plastic "loop" tabs - one on each side and one at the top. I was able to use a "hook" tool to reach in and pry each tab up. I bet if you bent a coat hanger wire you could do the same.

Let's start showing our photos here once we are done. Anyone finished yet?

I'm about 1/2 done... Dealing with some "technical difficulties" - e.g. I left these in the oven too long. I need another set of lights to finish up.

^^^^ That's not good, let me know if you need help in finding another set. I might know someone. How long and at what temps did you leave them in? Did you forget to set the timer?

I just bought a pair on ebay... So, I rubbed those down with steel wool, and washed them, then popped them in the oven to dry before painting black. I set the timer (in the garage, and the oven is in the garage) for 10 minutes. When into the house, started discussing xmas presents for the kids with my wife... then - "Oh Crap! I have stuff in the oven!" They were in for about 20 minutes.

You always gotta have a timer on you like a Casio watch. I burned enough BBQ chatting with friends, even with my automatic Swiss time pieces. It helps to have even a cheap Casio digital with an audible alarm on your wrist for those occasions.

Quotes source post: 10949338

I've created a thread on its own for those tips & tricks, pictures etc. We've high jacked this thread more than we could already Please use this thread instead: https://rennlist.com/forums/996-foru...and-986-a.html

Here's a photo of the ones I just installed.

It now seems like this mod can be done even less expensively. $38 http://www.ebay.com/itm/2x-2-5-Mini-...5c1c9c&vxp=mtr $29 http://www.ebay.com/itm/HID-Kit-Xeno...875db8&vxp=mtr

Edit: post deleted, unfair to those trying to do business out there sry!