Well I decided that since this was going to be a dedicated track car the need for Xenon headlights was non existent. I will never run it at night or on the streets anymore. The Xenons are very bulky (I need the room under the hood), somewhat heavy at 3.6Kg each (7.9 lbs) for a total of 7.2Kg (15.8 lbs). BTW, my Xenons are for sale.

However I still wanted some lights upfront for running in HPDEs in bad/rainy weather conditions as to be seen by other cars. I also wanted the turn signals to work because some clubs give the passing cue by using the flashers. Furthermore I wanted to keep the clean look of the front end of the B6 and its aerodynamic shape.

So I came up with a clever solution. I bought a used pair of B6 A4 Halogen headlamps from someone locally for $C100 for this mod which is cheaper than buying a new set on eBay. The solution was simple but the execution a little harder to do (for me). So I gave the job to Eric from Fab in Motion. He specializes in plastic mouldings and can make any plastic components by moulding them with his specialized equipment.

In this process I saved more weight which is always good especially off the front upper end of the car. The weight saved was 2.4Kg or 5.3 lbs for each unit for a total of 4.8Kg or 10.6 lbs.


So this is how we did it. First we gutted the inners and then cut the outer portion to the size and shape we wanted.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight002-Oct2009.jpg


Then we detached the lens and marked a patten of the design we wanted to use.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight003-Oct2009.jpg


The yellow side marker was removed.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight004-Oct2009.jpg


A cardboard cut out was used to test fit a backing plate.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight005-Oct2009.jpg


Once the shape was finalized, the plastic versions were cut.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadlightMod006-Oct2009.jpg


Here's how they look once temporarily installed.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadlightMod007-Oct2009.jpg


But before the final installation small holes had to be drilled into the plastic. Once the holes drilled the inner portion was painted with a special grayish paint. The plastic was then secured in place.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight008-Oct2009.jpg


Now all the main cluster clusters (9 LEDS/cluster) of super bright white LEDs were installed. For the flashers five 5mm super bright amber LEDs were used. All the wiring was secured together and exited the back side of the head lamp.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight011-Oct2009.jpg


Finally a black plastic cover was cut to size and shape and then glued into place to seal the unit.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight012-Oct2009.jpg


Here are the two units back to back. For those who have removed and handled the regular Xenons you can appreciate the size difference between the two. Unfortunately they did not send me a picture of a regular version vs. the modded version. But I'm sure you can tell the difference in the depth of both units.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight013-Oct2009.jpg


Finally here's the front view of the head lamp. The white plastic in which the LEDs are installed is painted in a grey shade. You can see the super bright white LED clusters.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight014-Oct2009.jpg


Here we have the white only LEDs in the on position.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight015-Oct2009.jpg


Here's a side view with the five amber turn signal lights turned on with the with LEDs.

http://i17.photobucket.com/albums/b79/mlab601/CAR-LEDHeadLight17-Oct2009.jpg

Dude, that's cool!