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Thread: Yet another projector retrofit tutorial: ZKW -> Morimoto Mini D2S 4.0

  1. #1
    Join Date
    Nov 2016
    Location
    Vallejo, CA
    Posts
    13

    Yet another projector retrofit tutorial: ZKW -> Morimoto Mini D2S 4.0

    Hello community. I've had my 2004 sedan for over a year, typical ZKW burnt bowls. After lots of research, last December, I finally decided to tackle this project. I went with Morimoto Mini D2S 4.0 projectors based on a few pictures I saw online. What drew me to this projector was the definition and width of the cutoff.





    The project is definitely not plug and play but if you have the tools it's another option to consider. I finally got through sorting over 150 pictures and instead of doing the step by step here, I annotated the images. Sorry for the few grammar errors, busy schedule so I was working at night.

    I'm making this tutorial newbie friendly so if you've never tinkered with your headlights you'll find useful pictures. However, by the time I was ready to install these things I kind of stopped taking pictures, too excited to see the lights in action. I did take pictures of the final result and a little driving clip included in the end.


    Components

    Morimoto Mini D2S 4.0 from Lightwerkz
    http://www.lightwerkz.net/index.php/...rojectors.html

    E46-R shrouds also from Lightwerkz
    http://www.lightwerkz.net/index.php/...r-shrouds.html

    Morimoto XB D2S 5500K bulbs
    http://www.lightwerkz.net/index.php/...d2s-bulbs.html


    Tools

    - flat blade screwdriver
    - pocket size flat blade screwdriver
    - phillips screwdriver
    - interchangeable bit screwdriver
    - 6" magnetic hex bit extension
    - T25 driver
    - T15 driver
    - 8mm socket
    - ratchet, 3/8" or 1/4" doesn't matter
    - ratchet extension (optional)
    - magnetic parts holder (optional)
    - locking clamp pliers or needle nose pliers
    - Dremel 3000 kit
    - drill
    - 1/16" drill bit
    - 3/32" drill bit
    - soldering iron w/ solder
    - 18-22 gauge heat shrink wrap
    - pick tools, various angles
    - Sharpie
    - pen
    - painters/masking tape
    - JB Weld
    - Blue Magic polishing cream
    - #6 x 1/2" phillips sheet metal screws
    - #6 - 32 x 3/4" machine screws with matching nuts
    - #6 flat washers
    - 1 1/2 flat corner braces

    Part 1

    Headlight removal

    step001 by fatherlemmisty, on Flickr

    step002 by fatherlemmisty, on Flickr

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    Now use your ratchet and 8mm socket to loosen the front screws
    step010 by fatherlemmisty, on Flickr

    For the rear screws you'll use your screwdriver with magnetic extension and T25 driver. (Not pictured.)
    step011 by fatherlemmisty, on Flickr

    step012 by fatherlemmisty, on Flickr

    step013 by fatherlemmisty, on Flickr

    step014 by fatherlemmisty, on Flickr


    Headlight disassembly

    Take your headlights inside the house, I recommend working on a table. Here's the Morimoto unit.
    step015 by fatherlemmisty, on Flickr

    step017 by fatherlemmisty, on Flickr

    This trim comes off pretty easy.
    step018 by fatherlemmisty, on Flickr

    step019 by fatherlemmisty, on Flickr

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    I believe this was a Torx 15 driver, sorry for the grammar.
    step032 by fatherlemmisty, on Flickr

    While this one Torx 25, but don't quote me on this haha
    step033 by fatherlemmisty, on Flickr

    step034 by fatherlemmisty, on Flickr

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    I meant the burnt projector bowl
    step040 by fatherlemmisty, on Flickr

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    step042 by fatherlemmisty, on Flickr

    step044 by fatherlemmisty, on Flickr

    The heat also burned the driver's side shroud. Bummer. I would've reused the OEM shrouds.
    step045 by fatherlemmisty, on Flickr

    For comparison, the ZKW lens is frosty while the Morimoto is all clear.
    step047 by fatherlemmisty, on Flickr


    Modifying and retrofitting

    Another side by side. Now it's time to measure and test fit before cutting the reflector plastic. The goal is to make the Morimoto projector fit and allow enough clearance between the shroud and top of the reflector.
    step048 by fatherlemmisty, on Flickr

    This side view gives you an idea of how far down the projector should fit.
    step049 by fatherlemmisty, on Flickr

    step050 by fatherlemmisty, on Flickr

    This diagram is to scale and shows you how the projector fits. Test fit by placing your projector on the reflector holding unit, it won't fit completely flat due to the protrusions on the rear of the bowl but you'll get a good idea of where the screws will go. The downside to this retrofit is that only the bottom portion of the projector can screw directly onto the plastic. Time to get creative.

    So looking at the diagram, you want the Morimoto projector to fit under, clear if possible, the top factory mounting holes. Also read my note on the angle of installation. Once you find the right spot, use a sharpie to mark off the area that you'll cut/grid off with the Dremel tool. Do the same for both sides.
    step051 by fatherlemmisty, on Flickr

    step052 by fatherlemmisty, on Flickr

    step053 by fatherlemmisty, on Flickr

    step054 by fatherlemmisty, on Flickr

    step055 by fatherlemmisty, on Flickr

    Go grab these goodies, you'll be needing them soon.
    hardware and compounds by fatherlemmisty, on Flickr

    At this point I had a nice flat mounting surface with enough top clearance. Place your projector on top, now take your pick tool and through the bottom mounting holes on the projector, make a marking on the reflector plastic for your pilot hole. Make a pen marking, verify, and then drill a pilot hole with the 1/16" bit, this gives you more accuracy. Follow up with the 3/32" bit. Test fit and screw the projector onto the plastic using your #6 screw. This allows you to move the projector while it's secure, now mark your second bottom hole and drill the same way.
    step056 by fatherlemmisty, on Flickr

    Take your flat corner braces (L bracket) and using the Dremel, shorten one side, cut right between the holes.
    step057 by fatherlemmisty, on Flickr

    I'm missing a picture here but what you'll do next is attach the L bracket to the top left or top right side of the projector in an inverse direction. The bolt head should be on the back of the projector, use a washer, then on the front use a washer and nut to secure the bracket and projector. The rest of the pictures explain it better!

    Find the best angle and now use your pen or pick to mark through the bracket where the last hole will be drilled to attach bracket onto plastic. After many attempts these are the hole locations I ended up using on the passenger's side.
    step058 by fatherlemmisty, on Flickr

    step059 by fatherlemmisty, on Flickr

    step060 by fatherlemmisty, on Flickr

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    Passenger's side close up
    step068 by fatherlemmisty, on Flickr

    step069 by fatherlemmisty, on Flickr

    step070 by fatherlemmisty, on Flickr

    Driver's side close up
    step071 by fatherlemmisty, on Flickr

    step072 by fatherlemmisty, on Flickr

    step073 by fatherlemmisty, on Flickr

    step074 by fatherlemmisty, on Flickr

    step075 by fatherlemmisty, on Flickr

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    step083 by fatherlemmisty, on Flickr

  2. #2
    Join Date
    Nov 2016
    Location
    Vallejo, CA
    Posts
    13
    Part 2

    Reassembly and reinstallation

    step084 by fatherlemmisty, on Flickr

    step085 by fatherlemmisty, on Flickr

    Correction, it was flat black paint.
    step087 by fatherlemmisty, on Flickr

    step088 by fatherlemmisty, on Flickr

    step089 by fatherlemmisty, on Flickr

    step090 by fatherlemmisty, on Flickr

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    Mounting the headlights back on the car is pretty straight forward. Reverse order is headlights, trim, and finally corner lights. Remember that the bottom of the headlight housing has two spaces where the bottom guides slide into. Also, watch out when you screw in the rear inner screw, it's a tight space and without the magnetic extension you may drop it and never see it again haha!

    On the car

    step109 by fatherlemmisty, on Flickr

    step110 by fatherlemmisty, on Flickr

    step111 by fatherlemmisty, on Flickr

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    step118 by fatherlemmisty, on Flickr

    Video of the lights on the road!



    After three months of use I've had no issues. Hope this helps!
    Last edited by fatherlemmisty; 03-22-2017 at 07:06 PM.

  3. #3
    Join Date
    Jan 2016
    Location
    Chicago area
    Posts
    1,626
    That is quite the DIY.

    Thanks for posting

  4. #4
    Join Date
    Nov 2014
    Location
    Portland, OR
    Posts
    9,095
    Quote Originally Posted by holyc0w View Post
    That is quite the DIY.

    Thanks for posting
    +1

    If I ever have to do this for my sister's car I'll be coming to this DIY guide.
    Last edited by BMWCurves; 03-23-2017 at 04:44 AM.

  5. #5
    Join Date
    Jun 2014
    Location
    Toronto, ON
    Posts
    1,161
    Awesome DIY! Thanks a lot for taking the time to write this up.
    anandoc

    2004 330i auto | ZPP, ZCW | Schwarz 2 (668) | schwarz (N6SW)

    aFe Stage-1 Pro DRY S intake | Morimoto FX-R 3.0 retrofit | ///M3 Seats (power, heat, bolster adj.) | ///M3 Strut Brace | ///M3 SMG Steering Wheel retrofit | OEM Alarm retrofit | GROM USB | Khoalty angel eyes


  6. #6
    Join Date
    Nov 2012
    Location
    22841
    Posts
    9,187
    Thanks for creating this DIY.

    Final cost of this project?

    His - 2004 Imola Red / Alcantara 330i | 6MT | ZHP |

    Her's - 2005 Black Sapphire Metallic / Black Leather 330i | 6MT | ZHP |

  7. #7
    Join Date
    Jan 2013
    Location
    Houston
    Posts
    1,567
    Nice love it . Until u do the swap ull realize how much the light difference is

    Sent from my SM-G935V using Tapatalk

  8. #8
    Join Date
    Nov 2016
    Location
    Vallejo, CA
    Posts
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    Happy to share!

  9. #9
    Join Date
    Jan 2011
    Location
    Martinez, CA
    Posts
    345
    Very nice & detailed DIY. Thank you for all of your hard work!
    2004 Imola Red over Black Leather. 6-MT, Navigation, Cold Weather Pkg (the wife loves them seat warmers!), 3.46 Diff, UUC Short-Shift Kit, Tranny Mounts, CDV Delete and iPod mount.

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