HID Lens replacement - DIY

[ModItNow]

Quick question. To anyone who is lowered. Have you had any issues with the height of the light beam? I've aligned mine with a headlight machine (I work at a shop) and it just seems low. Wondering if I have to do this by eye... And also, adjusting the cutoff, how far away would you recommend? I've got a nice sharp cutoff but I've been adjusting per a wall about 15 feet away

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I adjusted the dials under the hood to raise them the same amount on both sides until it looked right (by eye) You might need to drive the car and readjust

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[audigsr]

Quick question. To anyone who is lowered. Have you had any issues with the height of the light beam? I've aligned mine with a headlight machine (I work at a shop) and it just seems low. Wondering if I have to do this by eye... And also, adjusting the cutoff, how far away would you recommend? I've got a nice sharp cutoff but I've been adjusting per a wall about 15 feet away

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I recommend 20ft. When I did this in the past I used painters tape on the wall and adjusted accordingly, this way you can see how much it raised when you adjust it.

[LionKing]

I recommend 20ft. When I did this in the past I used painters tape on the wall and adjusted accordingly, this way you can see how much it raised when you adjust it.

I ended up messing with it yesterday. I set height again with the machine but definitely raised out of spec just because I'm lowered. When I first did it, the beam was barely letting me see the bottom of people's tires.
I set the cutoff about 50ft back but I may bring it closer today and adjust it, maybe the 30ft will be a sweet spot.

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[jvoJR]

so these have the same description it seems, and both are $40, does it matter which we go with? I'm planning on doing this to my b8 S4.

https://www.lightwerkz.net/index.php...lear-lens.html

https://www.theretrofitsource.com/zk...ect_restrict=1

I had also planned on replacing the "lense covers" at the same time :)

[Turbocoop]

so these have the same description it seems, and both are $40, does it matter which we go with? I'm planning on doing this to my b8 S4.

https://www.lightwerkz.net/index.php...lear-lens.html

https://www.theretrofitsource.com/zk...ect_restrict=1

I had also planned on replacing the "lense covers" at the same time :)

Probably the same exact lens, it's what I used and it works fine. Definitely better than OEM

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[ps2cho]

So is the consensus if you get the ZKW-R lens without the notch, and you punch in the factory notch on the housing it won’t need any spacers?

I need to go back and correct my upgrade because my cutoff is not great but I installed the lens without punching the notch in, so I think it’s messed it up a little and I do get a lot do orange “hue” at the top of the beam pattern.

[LionKing]

So is the consensus if you get the ZKW-R lens without the notch, and you punch in the factory notch on the housing it won’t need any spacers?

I need to go back and correct my upgrade because my cutoff is not great but I installed the lens without punching the notch in, so I think it’s messed it up a little and I do get a lot do orange “hue” at the top of the beam pattern.

Correct. It needs to sit flush.

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[SteveYem]

For those who have done this mod recently, was the diameter of your clear lens small enough to allow it to seat all the way into the lens housing, after you flattened the 'notch' in the housing?

[LionKing]

For those who have done this mod recently, was the diameter of your clear lens small enough to allow it to seat all the way into the lens housing, after you flattened the 'notch' in the housing?

Also yes

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[SteveYem]

Also yes

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Thanks for confirming. I may need to order a pair of these updated lenses and revisit the retrofit. I never like the unknown that the lens seating vs. spacers introduced and was never convinced that I was achieving optimal results. Worth the cash to better fitting parts and try again. Although I have to say, it would be really nice if they could have included that notch while they were revising the design..

[LionKing]

Thanks for confirming. I may need to order a pair of these updated lenses and revisit the retrofit. I never like the unknown that the lens seating vs. spacers introduced and was never convinced that I was achieving optimal results. Worth the cash to better fitting parts and try again. Although I have to say, it would be really nice if they could have included that notch while they were revising the design..

I asked on order. They said they used to but because its becoming more universal, without the notch was where they decided the design should end up.

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[SteveYem]

I asked on order. They said they used to but because its becoming more universal, without the notch was where they decided the design should end up.

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Gotcha. Thanks for that info.
I haven't tried it yet so I'm curious - does the raised 'notch' in the holder hammer out of the way easily? Any tips you could share on how to flatten it carefully without negatively affecting any other part of the housing?

[LionKing]

Gotcha. Thanks for that info.
I haven't tried it yet so I'm curious - does the raised 'notch' in the holder hammer out of the way easily? Any tips you could share on how to flatten it carefully without negatively affecting any other part of the housing?

I laid it on the bench face down, took a flathead screwdriver against the raised notch, and tapped the end of the screwdriver with a hammer. It is fairly soft but takes a couple tap tap tap-er-roos. Just tap until it is flush, you dont have to go crazy

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[3.0ss]

I just ordered the ZKW's for my pre-facelift and 3 hours later cancelled the order after reading this thread lol. I have no problem taking the headlight apart and swapping the lens but I don't really want to mess around with spacing, washers and constantly adjusting it. So it is possible to just swap the lenses, no spacers, throw it all back together and done? Then maybe just adjusting the RV shield once assembled? I really want to do this mod when I throw on my clear sidemarkers but it sounds like its a 50/50 of people saying it was an easy install and others having to space, cut, and constantly adjust which sounds like a nightmare to me. Could anyone comment on if this lens is kind of a "plug and play" or does it require a lot of modification to the headlight housing?

[abrahamdlt09]

I just ordered the ZKW's for my pre-facelift and 3 hours later cancelled the order after reading this thread lol. I have no problem taking the headlight apart and swapping the lens but I don't really want to mess around with spacing, washers and constantly adjusting it. So it is possible to just swap the lenses, no spacers, throw it all back together and done? Then maybe just adjusting the RV shield once assembled? I really want to do this mod when I throw on my clear sidemarkers but it sounds like its a 50/50 of people saying it was an easy install and others having to space, cut, and constantly adjust which sounds like a nightmare to me. Could anyone comment on if this lens is kind of a "plug and play" or does it require a lot of modification to the headlight housing?

I haven't done any mods on my b8.5 but on my previous gti I had swapped the projectors for a set of morimoto d2s 4.0 and the output was gorgeous. I'm planning on doing the same with the b8.5 but based on my research I will need adapters for AFS, but I believe the "G5-R" projectors are a direct swap If you don't have AFS and they are D3S. Probably less headache than swapping the lens on stock projectors. Contact EMtuning on ig. They have helped me a lot


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[3.0ss]

I haven't done any mods on my b8.5 but on my previous gti I had swapped the projectors for a set of morimoto d2s 4.0 and the output was gorgeous. I'm planning on doing the same with the b8.5 but based on my research I will need adapters for AFS, but I believe the "G5-R" projectors are a direct swap If you don't have AFS and they are D3S. Probably less headache than swapping the lens on stock projectors. Contact EMtuning on ig. They have helped me a lot


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Oh ok thanks, just sent them a message. So the projector swap would be much easier than trying to swap just the lenses out? Would I be able to use the same bulbs I have now?

[abrahamdlt09]

Oh ok thanks, just sent them a message. So the projector swap would be much easier than trying to swap just the lenses out? Would I be able to use the same bulbs I have now?

IMO it's easier to swap the projector once you have the headlight disassembled, at least that was my case with the gti. Although it is also more expensive, but definitely worth it! If I remember correctly, G5-R are d3s so yes, you can use stock bulbs and ballasts.


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[SteveYem]

IMO it's easier to swap the projector once you have the headlight disassembled, at least that was my case with the gti. Although it is also more expensive, but definitely worth it! If I remember correctly, G5-R are d3s so yes, you can use stock bulbs and ballasts.


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I'm curious to know whether those projectors are actually a drop-in swap for the OEM B8.5 projectors. At the time I was screwing around with modding these headlights a couple years ago, I was not able to find any direct drop-in complete projectors so I ended up going down the lens swap route which was tedious and full of variables.

[3.0ss]

I'm curious to know whether those projectors are actually a drop-in swap for the OEM B8.5 projectors. At the time I was screwing around with modding these headlights a couple years ago, I was not able to find any direct drop-in complete projectors so I ended up going down the lens swap route which was tedious and full of variables.

This is the response I got from EMtuning, looks like they are a drop in kit with some custom brackets. Not sure if it’s worth the $200 or if the ZKW-R lenses will yield identical results for way cheaper. IMG_9447.JPG


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[3.0ss]

So I've been messaging EMtuning all day and they do in fact have a plug and play projector kit for our cars. They're the NHK G5's and he fabricates custom brackets and adapters so it's a pretty easy install. Total is about $240ish w/ shipping from the UK but I think it might be worth it considering you won't have to modify the stock housing in any way or have to do a bunch of adjustments to get the cutoff line just right. I think I might have to bite the bullet and order a pair.

[Ashtonts]

The ZKW-R lenses are a direct fit on these cars. No spacers needed. The set I purchased had a notch and were a direct fit. But if punching a notch in is too difficult, I don’t think this is a good DIY mod for you.

The light output is noticeably better than stock. I’m sure other kits could optimize the distance and glass to get more optimal results, but for the price the ZKW-R lenses are a nice drop-in upgrade

[Vivia1982]

Although it is an old post, I can still learn knowledge

[3.0ss]

The ZKW-R lenses are a direct fit on these cars. No spacers needed. The set I purchased had a notch and were a direct fit. But if punching a notch in is too difficult, I don’t think this is a good DIY mod for you.

The light output is noticeably better than stock. I’m sure other kits could optimize the distance and glass to get more optimal results, but for the price the ZKW-R lenses are a nice drop-in upgrade

I was planning on just doing the lenses because they are so cheap and now I know they're a direct fit but honestly after I saw pictures comparing the clear lenses on stock projectors to upgraded projectors it sealed the deal for me lol.

[03redgti]

So I've been messaging EMtuning all day and they do in fact have a plug and play projector kit for our cars. They're the NHK G5's and he fabricates custom brackets and adapters so it's a pretty easy install. Total is about $240ish w/ shipping from the UK but I think it might be worth it considering you won't have to modify the stock housing in any way or have to do a bunch of adjustments to get the cutoff line just right. I think I might have to bite the bullet and order a pair.

damn thats not a bad price at all! I'm def interested in this!

[3.0ss]

damn thats not a bad price at all! I'm def interested in this!

Just ordered mine, paid $256 and they should be here by next week. I'll share some pics when I get them on. Can't wait to actually be able to see at night lol!

[ReDeViL]

Just ordered mine, paid $256 and they should be here by next week. I'll share some pics when I get them on. Can't wait to actually be able to see at night lol!

more details on this would be great.
Really frustrated with the B8 lamp's lack of output.....

[3.0ss]

more details on this would be great.
Really frustrated with the B8 lamp's lack of output.....

Yeah so he sells Hella G5 projectors which work with the OEM bulbs and ballasts and he fabricates custom mounting brackets, shrouds, and adapters that plug into the shutter wire so it’s as simple as removing the old projectors and screwing in the new ones. Here’s a picture of the shrouds he makes to fit on the new projectors, once they’re made he sends them off to the paint shop and you could get them done in whatever color you want. You could also get etched lenses for an extra $50 if you’d like, I opted for just the clear lenses. He sent me a picture of just the clear ZKW-R lenses on an S4 and a picture of the new G5 projectors on a Merc and holy cow the light output is 20x better. If you’re interested in getting a pair, hit up EMtuning on Instagram or email him, he can answer any other questions you have!
https://emtuning.co.uk/
IMG_9505.JPGIMG_9506.JPGIMG_9507.JPG


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[ReDeViL]

Yeah so he sells Hella G5 projectors which work with the OEM bulbs and ballasts and he fabricates custom mounting brackets, shrouds, and adapters that plug into the shutter wire so it’s as simple as removing the old projectors and screwing in the new ones. Here’s a picture of the shrouds he makes to fit on the new projectors, once they’re made he sends them off to the paint shop and you could get them done in whatever color you want. You could also get etched lenses for an extra $50 if you’d like, I opted for just the clear lenses. He sent me a picture of just the clear ZKW-R lenses on an S4 and a picture of the new G5 projectors on a Merc and holy cow the light output is 20x better. If you’re interested in getting a pair, hit up EMtuning on Instagram or email him, he can answer any other questions you have!
https://emtuning.co.uk/
IMG_9505.JPGIMG_9506.JPGIMG_9507.JPG


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I assume the 2nd pic is from your ride after you swapped them in?

[3.0ss]

I assume the 2nd pic is from your ride after you swapped them in?

I haven’t received them yet, it’s an old Mercedes with the G5’s he swapped in


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[3.0ss]

Here’s a pic he just sent me of everything ready to ship out, should get them installed either this weekend or next. I’ll post a lengthy review once I get them on.
IMG_9602.JPG


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[ReDeViL]

Here’s a pic he just sent me of everything ready to ship out, should get them installed either this weekend or next. I’ll post a lengthy review once I get them on.
IMG_9602.JPG


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great, do update us once its done, and it may be good to get "before/after" pics of the light output and cutoff just so you can compare the differences.

[3.0ss]

great, do update us once its done, and it may be good to get "before/after" pics of the light output and cutoff just so you can compare the differences.

Just finished up today, my headlights look brand spankin new! I'm taking them in to get PPF applied on Monday so I'll share some output before/after pics out on the road Monday night. When I turned them on in my garage though the cutoff was laser sharp and they seem a lot brighter, although I was 3ft away from a wall lol! Install was super simple, literally just unscrewed the old one, screwed this one in, plugged it in, done. While I had my headlights apart I also replaced the amber sidemarkers with clear ones as well as replaced the headlight housing lenses so my light output should be 50x better than what is was. Here's some pics during the install.
4AA32CBA-0A87-49ED-BCC3-DAEC908BEE92.jpg IMG_9654.JPG IMG_9655.JPG IMG_9660.JPG IMG_9665.JPG IMG_9658.JPG IMG_9669.JPG


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[3.0ss]

I was able to snap some pics of the cutoff line on my garage door from about 15ft away and my oh my the difference is insane. The new cutoff and high beams are gorgeous!

IMG_9688.JPG IMG_9689.JPG IMG_9687.JPG IMG_9690.JPG


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[HOJeepster]

This is awesome, I think going G5 projectors is a better overall solution. I tried ZKW lenses on my B6 S4 headlights and was never all that impressed. I think swapping in a new retrofitted projector is the way to go.

[SteveYem]

I was able to snap some pics of the cutoff line on my garage door from about 15ft away and my oh my the difference is insane. The new cutoff and high beams are gorgeous!

IMG_9688.JPG IMG_9689.JPG IMG_9687.JPG IMG_9690.JPG


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Those results look great! Now the important question - with that sharp cutoff and increase light output are you getting high-beam flashed by oncoming drivers all the time? That's what happened to me after I retrofitted ZKW-R clear lenses into my OEM projectors, and the only way to avoid it was to aim my headlights so far down that they became mostly useless.

To be clear, I would love to do this mod because I have not been super happy with the ZKW-R lens retrofit solution, but I would hate to end up in the same boat as far as blinding oncoming traffic is concerned.

[3.0ss]

Those results look great! Now the important question - with that sharp cutoff and increase light output are you getting high-beam flashed by oncoming drivers all the time? That's what happened to me after I retrofitted ZKW-R clear lenses into my OEM projectors, and the only way to avoid it was to aim my headlights so far down that they became mostly useless.

To be clear, I would love to do this mod because I have not been super happy with the ZKW-R lens retrofit solution, but I would hate to end up in the same boat as far as blinding oncoming traffic is concerned.

I haven’t been flashed once in the hours of night driving I’ve done since installing them. I set up a car about 30ft away from mine and aimed the beam right below the windshield so I’m in that sweet spot of being able to light up the road while not blinding others.


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[SteveYem]

I haven’t been flashed once in the hours of night driving I’ve done since installing them. I set up a car about 30ft away from mine and aimed the beam right below the windshield so I’m in that sweet spot of being able to light up the road while not blinding others.


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Smart move using another car as your reference!
I should also clarify, I get flashed most when I am "up hill" from an oncoming car, so even when my lights are adjusted low it doesn't help them in this scenario. I think the dimpling / fresnel texturing of the OEM lenses blurs the cutoff line which prevents opposing drivers from getting that sharp flash as they pass through the cutoff line - but I suppose that's just to be expected from these clear lenses.

[3.0ss]

Smart move using another car as your reference!
I should also clarify, I get flashed most when I am "up hill" from an oncoming car, so even when my lights are adjusted low it doesn't help them in this scenario. I think the dimpling / fresnel texturing of the OEM lenses blurs the cutoff line which prevents opposing drivers from getting that sharp flash as they pass through the cutoff line - but I suppose that's just to be expected from these clear lenses.

Yeah it does while sacrificing light output sadly, nothing we can do about it on hilly roads. At least it's not constantly blinding other drivers like those lifted trucks/Jeeps with LED headlights lol!

[SteveYem]

Yeah it does while sacrificing light output sadly, nothing we can do about it on hilly roads. At least it's not constantly blinding other drivers like those lifted trucks/Jeeps with LED headlights lol!

After a couple of months, how is the honeymoon period going? Is your headlight output now similar to the "late model Acura MDX" in terms of whiteness, brightness and cutoff sharpness and coloration? Or does it fall short of that benchmark in any way?

I ended up contacting the guy selling the projector+adaptor kits in the UK and am ready to pull the trigger, but in the back of my mind I'm worried that my results still won't get me on par with the other luxury cars out there that have brighter, whiter beam patterns with sharper cutoff than the S4. Having been down the road of retrofitting clear lenses and Philips WhiteVision D3S bulbs into my stock projectors and not being thrilled with the outcome, I'm a bit leery of this approach as well. But maybe (hopefully!) you can prove my apprehension to be unfounded!

[3.0ss]

After a couple of months, how is the honeymoon period going? Is your headlight output now similar to the "late model Acura MDX" in terms of whiteness, brightness and cutoff sharpness and coloration? Or does it fall short of that benchmark in any way?

I ended up contacting the guy selling the projector+adaptor kits in the UK and am ready to pull the trigger, but in the back of my mind I'm worried that my results still won't get me on par with the other luxury cars out there that have brighter, whiter beam patterns with sharper cutoff than the S4. Having been down the road of retrofitting clear lenses and Philips WhiteVision D3S bulbs into my stock projectors and not being thrilled with the outcome, I'm a bit leery of this approach as well. But maybe (hopefully!) you can prove my apprehension to be unfounded!

Oh man I love them. The cutoff is laser sharp with a nice deep blue hue, color wise they are a nice bright white, and the brightness is very impressive, they have exceeded my expectations in terms of the distance/width/and brightness. When I look at comparison pictures of the OEM projectors I'm just wowed at how dark the old ones were. The brightness and intensity of the new projectors is so, so much better, and I'm in love with the blue cutoff flashing off of buildings and road signs. The highbeams are also very impressive, they shoot a very tall wall of light a mile down the road lighting up everything! I've started paying more and more attention to other cars headlights on the road comparing them to mine and these are certainly on par with the newer luxury vehicles in terms of color and brightness. I am very pleased with them!