I have decided to try out a little project I've been thinking about for a few months. I have been looking to build myself some headlights using a pair of replacement clusters and fitting some DRLs to them in some way.
I have considered buying some "switchback" strips to act as both DRL and indicator strip. These negate the need for the indicator power drop as they turn the complete white LEDs off and turn on the amber ones in their place.
Something else I have considered fitting is Bi-Xenon modules to the full beam reflector giving me quad dipped beam and double full beam, and even thought about fitting all 4 units with Bi-Xenon projectors for total overkill. You can get these retrofit units from loads of places and screw into the reflector of normal dipped beam headlights.
I did however want the headlights to still conform to the normal function of a newer headlight, with the normal electronic height adjustment, and the DRLs to behave correctly with regard to the power output changes in different modes.
After doing some research I think I have got the hang of what the DRLs do in different states.
First they come on at full brightness when the ignition is live and running.
Secondly, when the headlights are fired up they drop to 30% power.
Thirdly, if the headlights are off the DRLs power down to 30% whilst the indicators are active so better visibility of the turn lamp is given.
At the moment I have got a wiring kit from ebay that will simulate the power change for the headlights on and turns them on with the ignition. I need to work out how to drive the indicator power drop. I have some ideas, but I'll work that out later.
After pondering and trawling ebay for suitable candidates I came across two auctions. One was for a full, but scratched, A5 facelift N/S cluster. The other was a set of the internal components from a O/S unit. Neither were particularity expensive (£95 in total for both) so off I went waving my Paypal account about.
Here is the full unit:
Got the parts delivered and had a quick size up:
Although the pictures look like the DRL is wider, its just the perspective and they are about the same width as the lens.
Generally speaking the shape and size of the DRL unit, including the profile of the front curve, were all pretty spot on although I might have to shave a small amount off the outer edges.
Projector-wise the existing dipped beam unit sits further toward the centre of the car than the A5 one so I will have to make some adjustments to the mounting arrangement. The B6 indicator will be coming out to be replaced with the standard A5 one that sits the other end nearer the grille. This should also make room for the 3" projector to sit between where the indicator and projector used to be.
The projector lenses are bigger in the A5, where the A4 ones were only 2.5". The reflectors themselves are the same size however, and the lens is further away.
Also I'm going to have to get a pair of D3S ballasts and 1 bulb/ignition unit. Either that or convert to D2 or D4 bulbs if space is tight and I can then move the ignition unit away from the back of the bulb.
The full beam solenoid:
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Striping down the A5 headlight.
The headlamp unit is sealed in a similar way to the one from the B6. Tongue and groove with sealant keeps the moisture out.
The A5 headlight also has some sprung clips around the unit along the top and bottom joins.
My intention was not to head/bake the cluster, and by damaging the plastic on the outer corner was able to get some plastic pry tools inside. Working my way around the join I slowly levered it apart:
This was the only section I had to damage, making the hole big enough, with a couple of fingers each side I was able to pull apart the two sections.
Leaving me with it looking like this:
Removing all the internal components was pretty easy, lots of T20 Torx driver required. The only one that is not accessable is circled on the next pic. The Torx screw can be reached by removing the chrome surround for the DRLs (with lots of patience) and removing the DRL optic tube. To be honest it wasnt my aim to be able to use the A5 headlights so I scored the plastic riser that hols the DRL bracket and applied some bending force till the plastic sheared.
The DRLs are driven in 3 segments, the top strip, and each of the lower curves. There are two electronic drivers for the DRLs, one drives the lower centre inner curve and a second beefier one drives the top and outer. As with LED lights these days the heat output from them is very high, so both drivers have huge heatsinks:
And with the plastic coupler taken off:
And the big double one:
Indicator reflector:
DRL units, one without Bi-Xenon surround (I do have both though):
Now I have a pile of bits ready for the conversion. Looking to buy another set of B6 clusters. I bought some DEPO ones to smarten the front end of my high miler and I wont be too worried about splitting a second set apart.
Part of the conversion will include painting the insides of the headlight black/dark grey, but I was considering adding some red somehow to match with all my other accessories, but not in your face, just some small discreet touches.......
.......will keep updating as I go on! Enjoy!
Cheers,
Rob
I have considered buying some "switchback" strips to act as both DRL and indicator strip. These negate the need for the indicator power drop as they turn the complete white LEDs off and turn on the amber ones in their place.
Something else I have considered fitting is Bi-Xenon modules to the full beam reflector giving me quad dipped beam and double full beam, and even thought about fitting all 4 units with Bi-Xenon projectors for total overkill. You can get these retrofit units from loads of places and screw into the reflector of normal dipped beam headlights.
I did however want the headlights to still conform to the normal function of a newer headlight, with the normal electronic height adjustment, and the DRLs to behave correctly with regard to the power output changes in different modes.
After doing some research I think I have got the hang of what the DRLs do in different states.
First they come on at full brightness when the ignition is live and running.
Secondly, when the headlights are fired up they drop to 30% power.
Thirdly, if the headlights are off the DRLs power down to 30% whilst the indicators are active so better visibility of the turn lamp is given.
At the moment I have got a wiring kit from ebay that will simulate the power change for the headlights on and turns them on with the ignition. I need to work out how to drive the indicator power drop. I have some ideas, but I'll work that out later.
After pondering and trawling ebay for suitable candidates I came across two auctions. One was for a full, but scratched, A5 facelift N/S cluster. The other was a set of the internal components from a O/S unit. Neither were particularity expensive (£95 in total for both) so off I went waving my Paypal account about.
Here is the full unit:
Got the parts delivered and had a quick size up:
Although the pictures look like the DRL is wider, its just the perspective and they are about the same width as the lens.
Generally speaking the shape and size of the DRL unit, including the profile of the front curve, were all pretty spot on although I might have to shave a small amount off the outer edges.
Projector-wise the existing dipped beam unit sits further toward the centre of the car than the A5 one so I will have to make some adjustments to the mounting arrangement. The B6 indicator will be coming out to be replaced with the standard A5 one that sits the other end nearer the grille. This should also make room for the 3" projector to sit between where the indicator and projector used to be.
The projector lenses are bigger in the A5, where the A4 ones were only 2.5". The reflectors themselves are the same size however, and the lens is further away.
Also I'm going to have to get a pair of D3S ballasts and 1 bulb/ignition unit. Either that or convert to D2 or D4 bulbs if space is tight and I can then move the ignition unit away from the back of the bulb.
The full beam solenoid:
------------------------------------------------------------------------------------------------------------------------
Striping down the A5 headlight.
The headlamp unit is sealed in a similar way to the one from the B6. Tongue and groove with sealant keeps the moisture out.
The A5 headlight also has some sprung clips around the unit along the top and bottom joins.
My intention was not to head/bake the cluster, and by damaging the plastic on the outer corner was able to get some plastic pry tools inside. Working my way around the join I slowly levered it apart:
This was the only section I had to damage, making the hole big enough, with a couple of fingers each side I was able to pull apart the two sections.
Leaving me with it looking like this:
Removing all the internal components was pretty easy, lots of T20 Torx driver required. The only one that is not accessable is circled on the next pic. The Torx screw can be reached by removing the chrome surround for the DRLs (with lots of patience) and removing the DRL optic tube. To be honest it wasnt my aim to be able to use the A5 headlights so I scored the plastic riser that hols the DRL bracket and applied some bending force till the plastic sheared.
The DRLs are driven in 3 segments, the top strip, and each of the lower curves. There are two electronic drivers for the DRLs, one drives the lower centre inner curve and a second beefier one drives the top and outer. As with LED lights these days the heat output from them is very high, so both drivers have huge heatsinks:
And with the plastic coupler taken off:
And the big double one:
Indicator reflector:
DRL units, one without Bi-Xenon surround (I do have both though):
Now I have a pile of bits ready for the conversion. Looking to buy another set of B6 clusters. I bought some DEPO ones to smarten the front end of my high miler and I wont be too worried about splitting a second set apart.
Part of the conversion will include painting the insides of the headlight black/dark grey, but I was considering adding some red somehow to match with all my other accessories, but not in your face, just some small discreet touches.......
.......will keep updating as I go on! Enjoy!
Cheers,
Rob
best of luck though, looking forward to progress :icon_thumright:
