The ZKW Burnt Bowls Thread

[cakM3]

Okay everyone! I completed Part 2 of my DIY and it is posted

Hope this will help others faced with what I was faced with

[sna77]

Charlie, great work! I am no way that brave though. Does anyone know how much the TFX retrofit from Lightwerkz costs? I'd rather just pay them to do it right for me.

Plus, I have access to 3 sets of e46 2002-2005 sedan headlights:
- AL halogen
- AL bi-xenon
- ZKW bi-xenons that came in the 330 and are currently in the car.

Does anyone know if you need the original ZKWs or can the retrofit be done with another set of headlights?

[nike001]

Charlie, great work! I am no way that brave though. Does anyone know how much the TFX retrofit from Lightwerkz costs? I'd rather just pay them to do it right for me.

Plus, I have access to 3 sets of e46 2002-2005 sedan headlights:
- AL halogen
- AL bi-xenon
- ZKW bi-xenons that came in the 330 and are currently in the car.

Does anyone know if you need the original ZKWs or can the retrofit be done with another set of headlights?

I forget, but when I asked him.. it was ~400-600

For the AL bi-xenon, are they a whole housing? Or just projectors

[sna77]

The AL ones are complete headlight assemblies...

[sna77]

Also, does anyone know what the back of their headlights look like? Do they utilize the existing mounting points for the ballasts etc, or am I zip-tieing things to the engine compartment which I haaaate

[cakM3]

Charlie, great work! I am no way that brave though. Does anyone know how much the TFX retrofit from Lightwerkz costs? I'd rather just pay them to do it right for me.

Plus, I have access to 3 sets of e46 2002-2005 sedan headlights:
- AL halogen
- AL bi-xenon
- ZKW bi-xenons that came in the 330 and are currently in the car.

Does anyone know if you need the original ZKWs or can the retrofit be done with another set of headlights?

Thanks Steve

I initially did the research from Lightwerkz and found this out:

"HID Projector Retrofit Conversions


HID Projector retrofitting requires you to provide a set of headlights for us to complete the final product. Pricing includes set of headlights to be converted, not including any additional product, shipping, or surcharge fees. All conversions come featured with a full craftsmanship and condensation warranty. Please read our Policy section for more details.


HID Projector retrofitting allows us to convert your current headlights with the best available technology. This highly specialized service we offer involves installing HID projectors into reflector-based headlights, or if the car already comes with projectors, we can replace them with ones of better quality and performance. This allows the customer to obtain the absolute best performance available on the market without any compromises. These conversions are hand built by our team on a per order basis so you can count on the attention to detail and high levels of quality.

Base labor costs on a single projector retrofit conversion range between $365-$960. Costs will vary depending on application type, sealant type, and parts used in the conversion. Please contact us directly for a quote on labor."

I know they do awesome work but that was just alittle more than I was willing to put towards these ZKWs. I found a solution that cost me less than $200 to do which is why I came out with this DIY. Believe me, I was intimidated to take on this project for fear of ruining these headlight assemblies and having to fork out $2,400 just to correct my very costly mistake. This is why I took my time to do the research and come up with my solution. Realizing that there was no all-encompassing retrofit DIY out there, I decided to post my solution.

If anything Steve, I'd swap put the ZKWs for the AL Bi-Xenons and call it a day. Lens swap from the ZKW headlights into the Al Headlights is possible but (assuming the lens holders are plastic), you have to be careful not to break any of the clips.

If you have any question on this let me know I'd gladly help

Steve... the AL headlight assemblies....if you mean complete assemblies as in they also have their own ballasts connected to the headlight assemblies (mounted underneath) then all you should have to do is plug them into the lighting harness of the car. Plug and Play.....it should work

[sna77]

Steve... the AL headlight assemblies....if you mean complete assemblies as in they also have their own ballasts connected to the headlight assemblies (mounted underneath) then all you should have to do is plug them into the lighting harness of the car. Plug and Play.....it should work

Thanks Charlie for the insight. Sounds like AL headlights are the superior product to ZKW ones then? If money / time wasn't a factor at all, what would be the best, most reliable solution? Simply purchasing a new pair of AL headlights which I assume are just plug and play to drop them in?

[danewilson77]

Steve... the AL headlight assemblies....if you mean complete assemblies as in they also have their own ballasts connected to the headlight assemblies (mounted underneath) then all you should have to do is plug them into the lighting harness of the car. Plug and Play.....it should work

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Thanks Charlie for the insight. Sounds like AL headlights are the superior product to ZKW ones then?

Yes.

HTC Thunderbolt+TT

[cakM3]

Steve,

I haven't gone this route but my guess is that if you were able to get a set of AL bi-xenon headlights for our sedans, they should just plug in and work. Since you have ZKW headlights, you can ( if you are brave enough ) swap out the AL lens for the ZKW lens

Then replace the headlight assemblies and still retain the ZKW clarity over the AL lens. A win in my book

[sna77]

Got it... So ZKW lenses with AL projectors. ha! Charlie, this might be a winter time project. I drive the wife's X3 during the winter mostly anyhow--the bi-xenons on that thing are night and day better than the ZHPs