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Slimline HID Ballasts -now fitted in Headlight

Discussion in 'A4/A4 cabriolet/S4 forum(B6 chassis)' started by Woorlord, Apr 13, 2009.

  1. Woorlord
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    Woorlord shifting to Hyperspace... . VCDS Map User

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    [Apr 13, 2009]
    Anybody wanting to fit HID's may want to consider the newer Digital Slimline Ballasts that "quattroJames" put me onto in his thread - quattrojames thread

    The Slimline HID kit used was off Ebay - LINK

    Before with standard size Ballasts I had.....
    [​IMG]

    And now I have everything self-contained within the Headlight assembly - with nothing hanging out!

    What I did...........

    1. New Slimline Ballast on a custom mounting plate I made - primed and painted:

    [​IMG]

    2. Did not use the waterproof connector for 12v connection as this will be in the headlight assembly - made up a custom connection using standard mini-crimp connectors. Also earthed the Ballast casing with an additional earth wire as it seems to be floating.
    [​IMG]

    3. This was the hardest part - getting the cables from the Ballast into the light assembly. I assume this part is normally cut out for factory fit OEM Ballasts. Anyway decided on a 40mm hole cutter located as shown. (Be careful as drill center will hit the back of the light reflector - but disconnect the motor actuator under the other access panel and this gives more internal clearance for the drill with the reflectors moved out the way.
    Also place a plastic bag inside the headlight assembly to catch any plastic swarf from hole cutting. Have a vacuum cleaner hose to hand to remove any stray swarf as you cut the 40mm hole - it's a pain to remove if it falls into the headlight assembly owing to static from the various internal plastic parts!!
    [​IMG]

    4. Hole from inside.....
    [​IMG]

    5. Put two layers of bathroom silicon sealant around the rim of the plate recess and let it set for 24 hours. This acts as a waterproof seal between the plate and the light assembly.
    [​IMG]

    6. Passed the HV unit and 12v connector through the 40 mm hole and mounted the Ballast plate with self tapping screws.
    [​IMG]

    7. Stuck the HV unit down with a couple of double sided sticky pads and made 12v connections with standard male flat spade connectors into Audi connector. HID bulb mounted and HT connections made.
    [​IMG]

    Repeated for other light and remounted to car - That's It All Done :moa:
    #1
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  3. golf
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    golf ***** rent boy VCDS Map User

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    [Apr 13, 2009]
    Good job, great pictures too. Mine are still loosely attached to various parts in the engine bay using cable ties.
    #2
  4. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Apr 13, 2009]
    Top job, very neat installation :salute:

    Luckily one of mine is hidden under my new cover, I had only just had the lights adjusted again after having the front off the car when my original ballast failed so I don't want to take the headlights out again!
    #3
  5. J7USS
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    J7USS Shuddup Foooool!!

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    [Apr 13, 2009]
    Top Job there. Cant believe how much smaller them ballast's are..
    #4
  6. Marc1
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    Marc1 Member

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    [Apr 14, 2009]
    Great install guide Woorlord. I did this with mine too, always meant to put a write up on though :ermm:. No need to now, thanks to you :applaus: Your install is a tad neater too. I used some all CD cases trimmed down and stuck to the underside of the headlight housing same place as you did but with no more nails, lol. This is a really neat solution IMO and as you say, it's where the OEM ballasts sit, so works really well and easy to contain everything when removing headlights.

    I'd just add that people following suit should be careful when cutting the hole that they don't get too many shards of black plastic floating around in the headlight - it was a right pain for me to clean once I'd realised.

    Cracking job :salute:
    #5
    Cobra88 likes this.
  7. Woorlord
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    Woorlord shifting to Hyperspace... . VCDS Map User

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    [Apr 14, 2009]
    Tesco's carrier bag stuffed inside the light assembly and a vacuum cleaner hose close to hand - and basically very careful when drilling the 40mm hole. This was the hardest part!

    Have only spotted one tiny piece of swarf in n/s light - nothing to worry about.

    HV WARNING Signs:

    Just to finish this project off, now after some small "High Voltage" Warning Triangles to stick on back of light cover which are not to big. The space available on the access cover is only 44mm x 44mm, and the sign I was after was something like one of these.........

    [​IMG] [​IMG]

    But these are too big at 50mm x 50mm.
    Labelsources Link

    May have to settle for these which are 30mm x 33mm....
    Link to TLC
    [​IMG]

    Anybody got any other sources for similar labels no larger than 44mm x 44mm ??
    #6
  8. sebbelcher
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    sebbelcher Member

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    [Apr 14, 2009]
    Are these things legal without the auto-levelling devices fitted OE?

    I'm seeing more and more of these after market devices fitted to older golfs, corsas and 206s (virutally anything) by the 'boy-racer' community and they are bloody annoying. I'm not sure if I have more sensitive eyes than the rest of the population but I can always tell the HID fitted cars because it usually results in me being temporarily blinded as they approach. They will usually get a good dose of my high-beams in return.

    People seem to have it in their heads that the brighter, the better, forgetting that it's probably better that the person driving towards you at 60mph can see where they are going!

    Not directed at anyone in this thread, just an observation.
    #7
  9. blackpool1974
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    blackpool1974 Member VCDS Map User

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    [Apr 14, 2009]
    Well the M.O.T testers should be failing people if they are incorrectly aligned or the car isn't suitable for them to be fitted safely.

    More of an annoyance to me are people carriers X5, Q7 etc etc they are so high up that they are blinding everyone
    #8
  10. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Apr 14, 2009]
    This has been covered lots and lots of times, what you are saying is correct, however our A4's have ellipsoidal headlights, so as long as the alignment is correct (which applies to halogen lights too) you will NOT dazzle anyone. The chav brigade fitting xenon bulbs to standard reflector headlights are the ones you are referring to ;)
    #9
  11. Woorlord
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    Woorlord shifting to Hyperspace... . VCDS Map User

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    [Jun 27, 2009]
    I have been asked for a connection diagram for my Slimline Ballast retrofit, so here it is......

    [​IMG]
    #10
  12. mrmule
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    mrmule Member

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    [Dec 31, 2009]
    Great write up woorlord, thanks. I followed your suggestions on installation with the ones I bought:

    http://cgi.ebay.co.uk/ws/eBayISAPI....552757&ssPageName=STRK:MEWNX:IT#ht_6382wt_941

    I even managed to squeeze in the decoders which came with it.

    As neat and tidy as the plate you fabricated is, are you not concerned about overheating of the ballasts?

    I decided it'd be better to leave it open to air. I stuck the ballasts in to the headlight case with a 6mm adhesive pad, normally used for number plates from Halfords. This way its not sitting on the headlamp support, so is protected from any water which may (unlikely) ingress that far back (plus they're waterproof anyway). The 6mm pad will act like a bit of a shock absorber too as it wont be touching anything hard. Lastly, there will still be ventilation, whilst remaining out of sight.

    They all work well, plus I have auto lights and it works fine with them.

    Fantastic mod, and highly recommended.
    #11
  13. Woorlord
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    Woorlord shifting to Hyperspace... . VCDS Map User

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    [Jan 1, 2010]
    Was not really concerned about heat from the ballasts - not really noticed any significant heat during testing, and also the mounting plate acts as a heatsink to dissipate the heat further.

    Thanks for your comments.
    #12
  14. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Jan 1, 2010]
    Also worth noting the OEM ones fit in the same place and they have no problems.

    Nice neat job Woorlord.
    #13
  15. chrisash32
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    chrisash32 Member

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    [Jan 1, 2010]
    wish my install was that good...
    my ballasts are just slightly too thick to put at plate over, but they are in the same place.
    Just wish i could stop these bloody ABS warnings!
    #14
  16. Woorlord
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    Woorlord shifting to Hyperspace... . VCDS Map User

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    [Jan 1, 2010]
    Where possible re-route the Crash sensor loom away from the HID ballast and HT cables where possible. When I changed my bumper I had ABS warnings on the DIS every time I switched on, although none before changing the bumper. All I can think is as the headlights were taken out, cable routes may have slightly changed. The crash sensors are either side of the radiator - small metal box.

    The crash sensor cables are meant to be "screened", so this would suggest they are susceptible to RF interference??
    #15
  17. mrmule
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    mrmule Member

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    [Jan 1, 2010]
    Agree, thats the best place for them, but do OEM ones have a plate over them?

    I think the passive cooling running over the top of the ballast would help it...

    [​IMG]
    Last edited: Jan 1, 2010
    #16
  18. iyrix
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    iyrix Member

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    [May 3, 2010]
    #17
  19. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [May 3, 2010]
    #18
  20. sebhar70
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    sebhar70 Member

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    [May 3, 2010]

    I don't know about that kit but I know this seller: http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=230355552757&ssPageName=STRK:MEWAX:IT does a good kit, I bought mine from them and I have had no problems for several months. Make sure you get the error canceller.
    #19
  21. iyrix
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    iyrix Member

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    [May 3, 2010]
    cheers guys, will get this ordered up tomorrow. Need to get my first mod on the car!
    #20
  22. scott b
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    scott b Active Member VCDS Map User

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    [May 3, 2010]
    so its H7 ones, do you need to order the shorter ones or are the standard ones fine

    cheers
    #21
  23. iyrix
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    iyrix Member

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    [May 4, 2010]
    #22
  24. Woorlord
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    Woorlord shifting to Hyperspace... . VCDS Map User

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    [May 4, 2010]
    Note: These are the LARGE Ballasts and not the newer "Slimline" ones - note the connectors on the actual ballast unit!

    Advice for all units: "CAN-BUS compatible" should mean no Bulb Warning error messages on the DIS - they could still however interfere with the crash sensors at switch on which would give you DIS "BRAKE" errors. There are many threads on this site covering these errors.
    #23
  25. iyrix
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    iyrix Member

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    [May 4, 2010]
    Now you have me worried. I think i might just go to halfords and buy normal bulbs...

    Actually... after reading this im not giving up just yet...
    http://www.audi-sport.net/vb/showth...fter-xenon-install-help&highlight=Xenon Error

    Will go ahead and order the slimline ones and see what happens! Im sure there will be problems!
    Last edited: May 4, 2010
    #24
  26. iyrix
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    iyrix Member

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    [May 6, 2010]
    The kit arrived this morning - all look slike good stuff. Going to attempt to fit them on Sunday

    [​IMG]

    [​IMG]

    [​IMG]
    #25
  27. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [May 6, 2010]
    Where are you planning on mounting the ballasts?
    #26
  28. nanafagis
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    nanafagis Member

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    [May 6, 2010]
    Very tidy job there Woorlord. I might do something like this myself as I have the slimline ballasts in mine. I just stuffed them at the back of my air filter and washer bottle against the padded heat shield right at the back of my engine bay, which is a bit of a shame seeing as there's room for them up front like you've done. I love finding little mods like this that anybody can do with a bit of thought!
    #27
  29. iyrix
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    iyrix Member

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    [May 6, 2010]
    Not too sure yet, dont really know what it looks like in there... will know more on sunday!
    Hopefully its an easy job, but i think it might take me a while. :D
    #28
  30. iyrix
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    iyrix Member

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    [May 9, 2010]
    Finally got these fitted today, it has been a mission... Still not 100% happy, few little things to finsih off but they are in and working.

    Does anyone know why the lights take a second longer to turn off? also when i lock the car the hazard button stays lite up for a few seconds. Apart from that they seem fine...

    any help would be great

    few pics so far:

    I used perspex to hold them in.

    [​IMG]

    [​IMG]

    Bright!

    [​IMG]

    [​IMG]
    #29
  31. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [May 9, 2010]
    Glad you got them fitted at last :)

    Do you mean the hazard warning switch stays illuminated? It typically stays on for about 30 seconds while the car powers down fully and the alarm arms itself. That now new, I assume its always done it?

    I've not noticed my HID's taking longer to turn off, they're off instantly. But I imagine it would be because the ballast will store power for a short period of time after its de-energized.
    #30
  32. iyrix
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    iyrix Member

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    [May 10, 2010]
    Yeah finally fitted, they look really good. Very happy with this mod :D

    Its funny what you dont notice until you worry that something is going wrong, I never noticed the Hazard switch before but that makes sense. Thanks.

    The HID lights turn off, but ithe dash lights take a about a 2 seconds longer to turn off.

    Thanks for everyones help. Hopefully that nothing will melt and they will be ok!
    #31
  33. Avant4me
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    Avant4me The're Graphite not black!!

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    [May 10, 2010]
    Sorry to be a pain, but if your ballast is fitted below the head lamp, how have you sealed up the connection back to the wiring loom? I cannot see the standard plug in your pics.

    Matt
    #32
  34. iyrix
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    iyrix Member

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    [May 10, 2010]
    It's all inside. It will make sense 100% when you take the back cover off the lights.

    I thought the same, the 2 little pins go into the standard light fitting...

    [​IMG]
    #33
  35. asad
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    asad New Member

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    [May 19, 2010]
    hi
    i was wondering if anybody can help,iv jus got new a3 on a 10 plate it has xenon headlights as standard with drl im after upgrading to 8000k lights got told i need to just get a d3s bulb i cant find any uk suppliers with this can anybody help please

    thanks asad
    #34
  36. fourcircle
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    fourcircle nj

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    [Nov 7, 2010]
    I don't suppose anyone has measurements for the plates to put in underneath to seal the ballasts in? It would be handy if I could do them in advance before taking the headlights out. I'll most likely be taking them out outside in sub zero temperatures and doing the cutting etc in my flat since I don't have a garage just now.
    #35
  37. John_
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    John_ ---__---

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    [Nov 9, 2010]
    Yeah i was about to ask the same question.
    Pic says 30 and 22mm or should it be cm?
    Mr. Woorlord, would you be so kind to help us out here? :readit:
    #36
  38. Woorlord
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    Woorlord shifting to Hyperspace... . VCDS Map User

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    [Nov 9, 2010]
    For all you lazy bods out there who do not posses a ruler here are the plate dimensions I have measured that should fit the OEM recess. Note that the actual recess is 136mm x 93mm, so the plate should fit if cut to 135mm x 92mm. I have also measured the position of the holes which should also line up - but may need a little fine tuning!

    I have taken these measurements from a broken headlight I have lying around my garage - these are not from the plates I made myself previously but probably not far off.

    [​IMG]
    :thumbsup:
    Last edited: Nov 10, 2010
    #37
  39. iyrix
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    iyrix Member

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    [Nov 9, 2010]
    Good man woorlord!
    They are lazy buggers! :D
    #38
  40. Woorlord
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    Woorlord shifting to Hyperspace... . VCDS Map User

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    [Nov 9, 2010]
    That's the location of the hole centre for the cable feed into the light internal!
    30mm and 22mm from the recess edge.
    #39
  41. John_
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    John_ ---__---

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    [Nov 9, 2010]
    Thanks for the effort, it is very much appreciated :cool:
    #40

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