The ZKW Burnt Bowls Thread

Steve,

They should fit. I swapped out the OEM M3 Bosh AL lens with my ZKW lens and they were a perfect fit. :thumbsup

I would be surprised to find out that the ZKWs on your car did not fit the AL projectors...:) To me, the way to go in your case is to swap out the AL lens with the ZKWs from your current headlights....FTW in my opinion :thumbsup

When you do this be sure to take pics of your burnt projector bowls so I can see just how bad yours are...:p You see how bad mine were - pics in my DIY :)

So my project today was to swap out my passengers side bowl with a new one I was lucky enough to come across. The light output now is amazing...Except the Drivers side (which used to be the "good" one) is now TERRIBLE! I'm still looking for one more bowl.....

Pics included:
http://i849.photobucket.com/albums/a...y/8c95b479.jpg

Mine actually burned off the chrome finish and the bowls became CLEAR!! You can see my hand right through the reflector!
http://i849.photobucket.com/albums/a...y/5ab4fc25.jpg

http://i849.photobucket.com/albums/a...y/4d012ae6.jpg

The way the reflector should look NEW is chrome inside the bowl and the outside part of the reflector still has an orangey tint.

You swapped out for new zkw bowl?

HTC Thunderbolt+TT

yeah, it was the cheapest option for right now. And I always like to maintain stock as much as possible.

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Originally Posted by 808ZHP

yeah, it was the cheapest option for right now. And I always like to maintain stock as much as possible.

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Hehe....even if stock has design issues?

HTC Thunderbolt+TT

Sadly, yes. The original ZKW light is superb when fully functioning so swapping the bowls every couple years doesn't seem that big a deal for me....if I can find them that is.

I just ordered a pair of E90 ZKW projectors and bowls. When they arrive, I'll do a write up, but from what I gather, it is a fairly easy retrofit.

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Originally Posted by edlvrt

I just ordered a pair of E90 ZKW projectors and bowls. When they arrive, I'll do a write up, but from what I gather, it is a fairly easy retrofit.

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I've read that they're a direct replacement. Just pop the old ones out and pop the new ones in!

Not so much. Be aware that this is nowhere near a direct replacement type activity. E90s use D1S bulbs, not D2S so you're totally on your own for bulb retention. Also you have to remove the adaptive lighting hinges, drill holes, remove tabs, etc. My first one took me probably 3 hours of fabbing and adjusting with hand tools.

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Originally Posted by zj96sc

Not so much. Be aware that this is nowhere near a direct replacement type activity. E90s use D1S bulbs, not D2S so you're totally on your own for bulb retention. Also you have to remove the adaptive lighting hinges, drill holes, remove tabs, etc. My first one took me probably 3 hours of fabbing and adjusting with hand tools.

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As far as bulb retention goes, that is a simple matter of getting D1S bulbs, no?

Has anyone tried repaining the burnt ZKW bowls with high-temp metalic paint or covering the burnt part with gold foil?

http://img149.imageshack.us/img149/5386/foiledgy1.jpg

Tried...I was the originator of finding the burnt ZKW bowls back in 2008 since I think my car had the most nighttime driving from the mileage. It's hard to tell when your lights are having issues because the reflective bowl material degrades over a long period of time. I am fortunate that every car in the household has xenons so I could tell when I compared against the other vehicles. Foil only helps about 10% and don't compare the light coming off the garage door because it's not accurate to what lays on the ground. I tried to contact places that do high temperature plating but there is nothing that I could find that worked with plastic. Maybe someone the USA has more luck due to population.

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Originally Posted by az3579

As far as bulb retention goes, that is a simple matter of getting D1S bulbs, no?

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D1S bulbs have integral ignitors (i think that's the part) whereas D2Ss do not....so, no, not really a simple swap. You'd have to replace the electronics of the light.

D1S:
http://ecx.images-amazon.com/images/...500_AA300_.jpg

D2S:
http://www.dodgeramaccessories.com/u...fbf4053a45.jpg

Projectors came in today. The lenses should be in tomorrow. Looks like I have a project for the weekend!

I just converted my driver's side with E90 bowls. There was a good amount of cutting on the E90 bowls, however no mods were needed to the existing E46 lights. And the swap was done by accessing from the back side. So the headlight itself did not have to be taken apart. The lighout output is like night and ... well... later that night after the retrofit. I do plan to do a write-up when I replace the other side.

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Originally Posted by nk_zhp

I just converted my driver's side with E90 bowls. There was a good amount of cutting on the E90 bowls, however no mods were needed to the existing E46 lights. And the swap was done by accessing from the back side. So the headlight itself did not have to be taken apart. The lighout output is like night and ... well... later that night after the retrofit. I do plan to do a write-up when I replace the other side.

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Ahhh.... So you just modified e90 bowls.

HTC Thunderbolt+TT

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Originally Posted by danewilson77

Ahhh.... So you just modified e90 bowls.

HTC Thunderbolt+TT

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yes, all and all I had to cut and test fit it about 20 times before it was perfect. There are some very important details in the process that I am hoping to document.

nk_zhp: I read this whole thread at one point but don't remember, is it easy to order just the E90 projector bowls new, or would I need to chase them in a junkyard?

Rovert: Thanks for the photos. To me it looks better than 10% improved in total light output, though I realize the ground pattern might not be so much improved, especially if it's the top of the bowl that throw light onto the ground in front of the car.

Since I recently figured out how to remove my headlights (thanks in part to a DIY here on ZHP Mafia), I might try foiling just the top part of my driver's side bowl to compare.

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Originally Posted by LivesNearCostco

nk_zhp: I read this whole thread at one point but don't remember, is it easy to order just the E90 projector bowls new, or would I need to chase them in a junkyard?

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Do not believe you can get the projectors new from BMW, so yes.. ebay and the likes.

Yeah, the E46 side of things never gets modified unless you use the old bulb retaining clip to make the new one.

I just looked at my burnt bowls yesterday will ravaging though some old items that have been replaced with mods.

I was thinking that I may end up retro-fitting FX-R's since I've been seeing their light output and nothing is ever seemingly good for me in regards to light output. I'll probably be able to sell these AL's from the M3 I got them from.

i liked the FX-Rs .... I just always felt like JB welding the things in there was so bush league. I guess if you really took your time and aimed them right that's probably the best light output solution. shrug.

You're selling AL's?

HTC Thunderbolt+TT

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Originally Posted by danewilson77

You're selling AL's?

HTC Thunderbolt+TT

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Whenever I decide on FX-R's I probably will.. Whether that be later this winter or in the spring. I need to build up some funds

I just recently noticed my light output was kinda getting washed out more on the driver side. Still adequate for now, so I'm definitely looking into this for the near future for upgrades. E90 seems to be the best cheap solution with a little DIY.

https://img.skitch.com/20111210-1jq7...1eu73k6u96.png

I have completed my E90 reflector swap. I added some notes and pictures to Charlie's thread in the DIY section. Look for post #29 http://www.zhpmafia.com/forums/showt...r-Retrofit-DIY

Overall, I am very pleased. Let me know it you have any questions.

edlvrt, thanks for adding to my DIY thread :thumbsup

This is exactly what I wanted. Have something that will help everyone in the community and we all add to make this DIY better :thumbsup

I didn't care about the tail light recall, but I really, really care about this. BMW could easily make this right.

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Originally Posted by Johnmadd

I didn't care about the tail light recall, but I really, really care about this. BMW could easily make this right.

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They really should. Though I finally have my lights fixed and working as they should have all this time, I have not given up on my efforts to get this recognized by the NHTSA. I plan on mailing them my old reflectors and a letter shortly. Everyone needs to do their part and continue to call in and file complaints. Be sure spread the word and have other affected owners do the same. POWER TO THE PEOPLE!

Ed, you're right here. I will be submitting my letter shortly...

What BMW should do is replace these headlight assemblies with the AL headlight assemblies that SNA77 had mentioned as the alternative solution. This is what he did to have workable headlights over the ZKWs...seen at this link:

http://www.zhpmafia.com/forums/showthread.php?5619-Another-option-for-bi-xenons-Magneti-Marelli-OEM-replacements

Steve has a lot of BMW knowledge as well :thumbsup

Will these parts fix my burnt bowls in my ZKW's?
http://www.theretrofitsource.com/pro...roducts_id=136

http://www.theretrofitsource.com/pro...roducts_id=131

I have a feeling the first item isn't a bi-xenon projector..

Or would this be a "good" fix?

http://www.theretrofitsource.com/pro...roducts_id=236

as well as the shrouds..

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Originally Posted by Johal E32

Will these parts fix my burnt bowls in my ZKW's?
http://www.theretrofitsource.com/pro...roducts_id=136

http://www.theretrofitsource.com/pro...roducts_id=131

I have a feeling the first item isn't a bi-xenon projector..

Or would this be a "good" fix?

http://www.theretrofitsource.com/pro...roducts_id=236

as well as the shrouds..

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The first link is the projector LENS, which is a ZKW-R. You don't need this, since you already have OEM ZKW lenses!
The second link is the shroud (The chome part that goes around the projector to make it look fancy)

The 3rd link are actual projectors, but they are morimoto. I just had morimoto bulbs, and I swapped my OE phillips back in until I can get new phillips bulbs. I'm blaming my lighting problems on the bulbs. Saddle up and get these:
http://www.theretrofitsource.com/pro...roducts_id=101

They already come with ZKW-R lenses (which are needed this time, because the projector is 2.5 inches instead of your OE ZKW's which are 3 inches)

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Originally Posted by nike001

The first link is the projector LENS, which is a ZKW-R. You don't need this, since you already have OEM ZKW lenses!
The second link is the shroud (The chome part that goes around the projector to make it look fancy)

The 3rd link are actual projectors, but they are morimoto. I just had morimoto bulbs, and I swapped my OE phillips back in until I can get new phillips bulbs. I'm blaming my lighting problems on the bulbs. Saddle up and get these:
http://www.theretrofitsource.com/pro...roducts_id=101

They already come with ZKW-R lenses (which are needed this time, because the projector is 2.5 inches instead of your OE ZKW's which are 3 inches)

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thanks man! So is this all I need?
http://www.theretrofitsource.com/pro...roducts_id=101

Should I get a shroud or can I re-use my old one?

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Originally Posted by Johal E32

thanks man! So is this all I need?
http://www.theretrofitsource.com/pro...roducts_id=101

Should I get a shroud or can I re-use my old one?

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I'm not sure if you need a shroud or not. I'm in the same boat as you..because I'm getting FX-R's, but I'm not sure if i need the shrouds yet or not. I would think that we do since the old projector is 3" whereas the new one is 2.5".

maybe someone will chime in here and tell us

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Originally Posted by nike001

I'm not sure if you need a shroud or not. I'm in the same boat as you..because I'm getting FX-R's, but I'm not sure if i need the shrouds yet or not. I would think that we do since the old projector is 3" whereas the new one is 2.5".

maybe someone will chime in here and tell us

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Alright, thanks for the response though!

Driving around town is not big deal due to all the other lights around me... But on the highway, I think my angel eye's are a main source of lighting for me...These ZKW's are absolutely horrendous.

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Originally Posted by Johal E32

Alright, thanks for the response though!

Driving around town is not big deal due to all the other lights around me... But on the highway, I think my angel eye's are a main source of lighting for me...These ZKW's are absolutely horrendous.

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I hear you. I retrofitted AL lights from an e46 M3 coupe last year, but now I'm looking into getting more light. I'll probably just retrofit FX-R's in to my old ZKW housings and then sell these AL ones as a whole for someone looking for a fix that doesn't involve them taking everything apart

Man what a day. So I decided to visit my local junkyard and tried reflector bowls from an X5, E39, E34, E36, E38, E90 and finally a facelift E46 with AL lights. NONE of them worked on my ZKW lights. All of the mounting holes were in the wrong spots. I even brought the entire housing home and tried to retrofit the AL light bezel and all into my housing, it is different and does not work.

So all that for nothing. However, tomorrow I am going to try something that may be a decent fix for now. I will update you all if it works!

OooOoo...I see a Smolckerizing coming!!! :roundel

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Originally Posted by Smolck

Man what a day. So I decided to visit my local junkyard and tried reflector bowls from an X5, E39, E34, E36, E38, E90 and finally a facelift E46 with AL lights. NONE of them worked on my ZKW lights. All of the mounting holes were in the wrong spots. I even brought the entire housing home and tried to retrofit the AL light bezel and all into my housing, it is different and does not work.

So all that for nothing. However, tomorrow I am going to try something that may be a decent fix for now. I will update you all if it works!

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No! It DOES fit! My current lights are from a pre-facelift COUPE (m3) and they fit! You need to get the mounting thing that goes UNDER the lights that attaches to the lights. The whole housing will swap over in place of your ZKW

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Originally Posted by nike001

I hear you. I retrofitted AL lights from an e46 M3 coupe last year, but now I'm looking into getting more light. I'll probably just retrofit FX-R's in to my old ZKW housings and then sell these AL ones as a whole for someone looking for a fix that doesn't involve them taking everything apart

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I went this route with my burnt out ZKW reflector bowls. I swapped them out for the OEM ///M3 AL projector bowls and swapped out the bosh lens for the ZKW lens. I liked the results...much more lighting from just the lens swap alone :thumbsup

I have a detailed DIY from doing this swap here: http://www.zhpmafia.com/forums/showthread.php?5445-ZKW-Burnt-Projector-Bowl-Repair-Retrofit-DIY

Smolck, take a look at the diy, it might help you out...:)