Headlight rebuild with mods
 

Bought the evo-xr projector kit from morimoto along with a few different projector shrouds, and a set of spare headlights(that I didn’t research first befor buying 2003 model perm seal ones lol)


So, the plan is to clean/restore the used 03 headlights and pop them in as loaners while I take my time with my original 02 xenon headlights.

I think I have narrowed it down to:

—Brand new lenses. Retaining the orange slice corner marker inserts.

—Painting the headlight inner housing cosmos black(to match my new interior trim set)

—using the “e55 look” projector shrouds as I like the broader permitter plateau that resembles titanium color, while deleting the fresnel high and low beam glass inserts.

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Most likely leave at that, but may try a few other subtle mods. Don’t care for angle eyes or anything that screams aftermarket, but do kinda want a bespoke look.


If anyone has any pointers on things they wish they had done differently, feel free to share!

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Nice. Thanks! Fixed it!


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I bought very ok aftermarket light assemblies for my 01 e53. I think you'll cold up with a winning solution.

To power the halos I used the O₂ heater power (not the ground).

Lol, so I mentioned I bought used 03 lights. So I swap them in as loaners while I crack pen the 02 lights.. only to find out the ones I pulled out of my car are permasealed lol. Bought yet another used set, this time off of a confirmed 2000 model.


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Any plans to fix assembly wiring? I looked a mine during a bulb replacement. Multiple wires have cracks. I have a post update extra set. I plan to clean them up for installation. Wiring on the extra set are not as bad.

^i took a peak at them and they do look like just a bunch of random wires dangling with bear up cloth tape wrapped around them. If I remember to address them I will, otherwise I’m just gonna button it back up and cross my fingers lol


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Permaseal lights can be opened. Check out this YouTube guide from a member here for info.

https://youtu.be/DUxKwmAcq68

Forgot I never updated this.

Ended up keeping the mod pretty simple — just swapped in new projectors and projector shroud, no paint.

New projectors make a yuuuuge difference in light output. Aesthetically, it’s a tiny bit too non-oem and not enough full custom, but still happy with the finished results.

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Nice job! Was the insulation on the wiring turning to powder for you or was it ok? I'm now too scared to do mine after discovering my angel eyes wiring had pretty much turned to dust....