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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. fourcircle
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    fourcircle nj

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    haha. thanks mate. I'm not lazy, I promise. I just need to do the install quite quickly since there's a snowstorm outside and it's about -5
    #41
  2. John_
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    John_ ---__---

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    We already grateful you measured it for us but you said: ''so the plate should fit if cut to 135mm x 95mm'' , but your drawing shows 92 mm
    So is it 92 or 95mm? my guess is 92mm. Can you confirm pls
    Last edited: Nov 10, 2010
    #42
  3. fourcircle
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    fourcircle nj

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    actually could you just make 2 for me, pre-drill them and drop round to fit them too? ;)
    #43
  4. Woorlord
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    Woorlord shifting to Hyperspace... .

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    You can do the work on the headlight inside in the nice warmth of your home! Easy to remove - just the electrical plug is a real pain thou to unplug.
    :cold:

    Ooops typo yes it's 92mm - have corrected original post.

    I'll get them Gold plated also so you do not need to paint them - should be with you by Christmas.
    :laugh:
    Last edited: Nov 10, 2010
    #44
  5. fourcircle
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    fourcircle nj

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    Good man. Make sure to go round the back to the staff entrance. the butler will let you in.
    #45
  6. fourcircle
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    fourcircle nj

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    I pulled my lights out today and finally got a chance to finish installing the HIDs tonight after the kids were in bed. what a difference! If my hands weren't so frozen after handling a ratchett and sockets in -5 I would have hung about longer to admire them
    #46
  7. CMD
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    CMD Pointing Forward's!!!!!!!!!

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    S**T That's dedication.
    #47
  8. fourcircle
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    fourcircle nj

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    haha. I'm stupid for not doing it before now. And if I wait any longer it will just get colder. holding a ratchett in -30s in January anyone? yoiks!
    #48
  9. CMD
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    CMD Pointing Forward's!!!!!!!!!

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    If the temp droped to -30 here in Wales i would just lock the door's and hibernate

    [​IMG]
    #49
  10. fourcircle
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    fourcircle nj

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    haha. thankfully it's expected here for a brief spell and people are equipped for it. Not a lot of people go outside unless they have to though. Even with an engine heater a car will take a bit of warming up. Roll on building a house with a big heated garage!! No more tools stuck to my hands when attempting mods in the winter :)

    edit** Sorry. Way off topic. I'll stop now.
    Last edited: Nov 14, 2010
    #50
  11. Avant4me
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    Avant4me The're Graphite not black!!

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    #51
  12. jbcalvin
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    jbcalvin Member

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    Regardless of DIS or not, buy the ones with the error modules, all B6's have CANBUS wiring and you will get error codes if you don't have the blocks...

    I am finishing building my new headlight units with the slim ballasts this week and will have them fitted by Thursday.....
    #52
  13. Avant4me
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    Avant4me The're Graphite not black!!

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    Just got mine today and fitted the drivers passenger side. At a push i could fit the ignitor inside the headlight just like woorlord did but would have to cut off the old gromits. Question is has anyone found a place to mount the code prevention module as its quite large. Would really like to make it all self contained in the headlight if possible.
    #53
  14. j033y
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    j033y Member

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    #54
  15. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    Its amazing how much smaller they are, mine are a couple of years old now so I expect they're even smaller these days:

    [​IMG]
    #55
  16. jbcalvin
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    jbcalvin Member

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    Avant4me,

    I fitted my error code cancellers to the top of the top of the headlight unit on the inside, there is a flat section just above the reflector unit that they will fit into, secured the same way as the HV unit, with double sided pads, keeps everything contained as per Woorlords guide, you just need a bit of trial and error as to where the cables go as it is a tight fit....

    Steve
    #56
  17. Avant4me
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    Avant4me The're Graphite not black!!

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    I feel some trial and error, swearing and sore fingers coming on. Was considering making a plate like woorlord did, but cutting out the original headlight base where he cut the 40mm whole, that would give a lot more room. Definitely want it all inside the headlight as its a lot easier to remove if my MOT guy spots the conversion.
    #57
  18. simon.m
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    simon.m Active Member

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    the MOT should be fine mine has just passed it and they did not evan notice them ;-)
    #58
  19. Woorlord
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    Woorlord shifting to Hyperspace... .

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    For A4/B6 headlights that take the OEM Ballasts and use D1S bulbs there is a large opening - found this picture the other day on the web when researching the OEM Valeo Ballasts I recently fitted:

    Left side: Factory HID headlight / Right side: H7 headlight

    [​IMG]

    There is an outline of where to cut this hole on the headlight if you look carefully (on mine there is anyway.)
    #59
  20. Avant4me
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    Avant4me The're Graphite not black!!

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    All done, cut a bigger whole so i could get the ignitor inside the unit. Code module fitted to roof of headlight with sticky pads, ignitor put in endways alongside bulb holder, and ballast underneath. Just waiting on my steel plates to act as a heat sink and seal it all up underneath.
    #60
  21. mememe
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    mememe Member

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    From time to time my amber brake light warning light comes on. The light doesn't work. However, when the warning light goes out, the brake light works. It can happen at any time with the lights on or off.

    I thought it might be down to the position of the HID ballast so, I've repositioned it. Would you guys take a look and see if it's ok to leave it here please.

    Thanks

    PS the radio is still poor with the lights on.

    [​IMG]
    Last edited by a moderator: Aug 20, 2014
    #61
  22. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    Thats exactly where mine is and I have no problems.
    #62
  23. fourcircle
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    fourcircle nj

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    Poor radio signal with the lights on would suggest an earthing problem to me.
    #63
  24. mememe
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    mememe Member

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    Ah ok guys thanks for that. It made no difference to the warning light. Guess I'll look elsewhere.

    Poor earthing of the ballast or radio?
    #64
  25. Paul_TDi
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    Paul_TDi Member

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    What size thread screws/bolts did you use to mount the plates to the headlight?

    Trying to buy and prepare everything before I take the headlights out.
    #65
  26. krisavant
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    krisavant 4th set of a wheels in a year

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    To stop ABS lights coming on...
    Re-wire the earth off the near side headlight plug.
    The headlight ground shares ground with a few other grounds, ABS being one if them.

    No. 10 wire on the plug, near side headlight you need to re ground.
    Last edited: Nov 5, 2013
    #66
  27. Paul_TDi
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    Paul_TDi Member

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    For anyone that doesn't have random bit of ally or perpex laying around for the bottom cover I ordered 2 pieces of 135mmx92mm 1.5mm ally from this ebay seller.

    I had looked at plenty of online shops but all wanted stupid delivery prices, cost this company £1.20 to send and others were charging up to a tenner! for a few quids worth of ally.

    But anyways this seller charged me £5 for the 2 sheets delivered.
    #67
  28. glenandem
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    glenandem Member

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    hi guys im thinking of upgrading my poor headlights but why are people fitting slimline and some the bigger ones, is it to tidy things up and have everything inside the headlight on slimmer ones?
    #68
  29. krisavant
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    krisavant 4th set of a wheels in a year

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    They're all slim line these days, just got smaller through out the years.
    #69
  30. glenandem
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    glenandem Member

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    ah right cool, so if i get a set do i have to do all this cutting away at the headlight or can i just fit the ballasts and put the units down the back somewhere?
    #70
  31. krisavant
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    krisavant 4th set of a wheels in a year

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    Some cram all the wires in by the lamp/bulb, some let it all hang out ;)
    You will need to cut/drill hole somewhere (usually the lid) to feed wires from ballast to etc.
    Easy enough.
    #71
  32. Paul_TDi
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    Paul_TDi Member

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    Sorry but no. Ballasts are certainly smaller but the "Slim" models you can cram everything inside the headlights which is was the DIY guide on the first page is for. If you get standard ones then they have to sit outside the headlight somewhere.

    I have bought a slim set for mine which were delivered today and there the size of say 2-3 place mats stacked. Although they do have separate blocks on the wiring which is a decoder and igniter I think. I helped fit standard HID's to my mates car at the weekend and the ballast was the size of rowntrees jelly blocks!
    #72
  33. krisavant
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    krisavant 4th set of a wheels in a year

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    Well I didn't even know they still sell the fat ones??
    Thought it was just slim line all the way these days..
    #73
  34. Paul_TDi
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    Paul_TDi Member

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    Immitation is the greatest form of flattery....

    Prepped the lights with silicon the day before, just the 1 bead did the trick for me. Aquarium silison was just what I happened to have in the tool box..

    [​IMG]

    As mentioned there was a line where the standard HID hole would be, although watch where your cutting as if I followed it in some places I would of cut to the outside.

    [​IMG]

    Cut out, bought a knife tip for the soldering iron, although used a hacksaw blade to cut the straights faster.

    [​IMG]

    Thankyou James for the diagrams, your measurements were spot on, my drilling skills were not..... couple of holes slightly out.

    [​IMG]

    There was nothing pretty about how I stuffed them inside as I had the igniter and a decoded block to fit in.

    So ta..dahhhhh sprayed with Hammerite Hammered! (it's what I want to use on the brake calipers eventually)

    [​IMG]

    Also did Kris's earth mod to solve the ABS issue.

    Thankyou to everyone input on the guide.

    Oh and M4 bolts for the holes.
    #74
  35. Jimmy TDI
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    Jimmy TDI Pro Tinkerer

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    I wish I had found this forum before I bought the Nightbreakers, as the only reason I didn't fit hids straight away was because I didn't want to cut holes into the headlight covers.

    A great guide and thanks for the drawing of the plate dimensions as I can just pass it onto my old man who is a steel engineer.
    #75

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