DIY: B5 A4 - How to install a DDM Slim Ballast HID Kit

[GetBoosted84]

For this write up I will be installing a 55w DDM Tuning Slim Ballast H7 5000k HID Kit on a 2001 Audi A4.

Please do not put HIDs in you non-projector housing. It's dangerous and stupid!

Also, you should always test your bulbs and ballasts before going through the process listed below so you can save yourself a headache.

Difficulty (1-10):
3 - Only because you need to drill a hole in the headlight

Time:
1 hour (including taking photos for this write up)

Supplies Needed:
DDM Tuning Slim Ballast H7 HID Kit
T30 Torx - For headlight removal
Dremel with cutoff wheel
2 pieces of plastic (about the size of a CD case)
Silicone
Velcro (optional)

Steps:
1) Remove headlights


2) Flip first headlight over to show the bottom section where a normal HID ballast would be if you had that option


3) Measure your plastic piece that will cover the HID ballast. I am using a clear CD case because it fits with little trimming required .



4) Get out the dremel with cutoff wheel and trim the plastic piece to cover the entire section where the HID ballast will be.


5) Drill / Dremel a small hole that is big enough to fit the ignitor but not too big.


6) Test fit the ballast in the headlight housing


7) Fetch some velcro or you can use the included two way foam tape. I opted for the velco since I had some commercial velco from another project and I like the idea of being able to remove the ballast fairly easy later on.


8) Clean the housing and ballast with alcohol then place two strips of velcro on the housing on the flat areas and stick the ballast to the housing


9) Now it's time to seal up that nice hole you put in your headlight housing. Get the silicone sealant and put a bead along the edge of the plastic and stick it to the housing. Please note: You can use weather stripping as another used did in their overview of the DDM install (link) but I like silicone. And Poopie loves when I use this stuff anyway


10) Start making connections. The wires will only connect in one way with the exception of the two wires shown below. Make sure you put the positive and negative wires in the right position before you install everything and think your HID kit is busted up.


11) Tuck all the wiring into the housing and get ready to seal everything up


12) Wait for the silicone to cure then re-install your headlights


13) AIM YOUR HEADLIGHTS!!!
http://www.modifieda4.com/web/tech/h...ht-aiming.html

14) And of course celebrate with a nice bottle of brew


I'll post up photos of the finished product tomorrow night. Just finished with everything so I need to let the silicone set before installing in the car.



Original/Discussion Thread: http://www.audizine.com/forum/showthread.php?t=258916

[GetBoosted84]

Great write up, i just asked for a write up because i'll be installing a similar set soon. Two questions:

Where did you get the silicone paste?
Are the 55w ones safe?

Perma-Text High Temp Gasket Maker (I had it laying around from my valve cover gasket job)

Stock halogens run at 55w and other people on here run the 55w kit so yes. Also if you are referring if they are safe for the road then I would say yes assuming they are aimed correctly.

I would say that looks like RTV red.

Bingo

looks clean man. i am so tempted to buy a kit or two but kinda want to see what the 55 watts look like b4 i do so get those pics up!!! haha

I'll post up some shots tonight for everyone.

[GetBoosted84]

Low Beams:


Low Beams w/ Fogs:


High Beams:


Low Beam Cutoff (on slanted driveway):


And a video of them starting up:
http://www.youtube.com/watch?v=g5Ya355KkgE