Thanks Weasel,

I will give it a try and use these LEDs from Radioshack which are higher output than the ones in the video by almost 10X.

This 5mm high-brightness white LED is ideal for hobbies and electronics projects.

• Ideal for hobbies and electronics projects
• High visibility, 5mm Round T-1 3/4
• Intensity 7000mcd (typical);viewing angle 30°
• FW current 25mA; FW supply 3.3 (typical), 3.6V (maximum)

If they compare well to my 4.8 AEs I will keep them. Otherwise it is back to the drawing board......

AE prototype
 

I made 2 molds and a proto type AE, I compared with the post face lift at dusk and they have about the same intensity. Now just have to make the final products and attach them to the head light shrouds....

Cutting all those little grooves and trying to be even enough with them must be one tedious job... not a bad end result though. Better than lots I have seen. I wonder if there would be ab easy way to add a reflective background to make it brighter?

I have some aluminum duct tape on the back of this one. It compares well with the OEs on my 4.8iS and that is bright enough for me. I admit that this is not the first one at all..... It takes some experimenting to figure out what to do and how to do it. But I think I am fairly close to making four that will work for me.

The LEDs are nominally 3.6V and I think I will use 4 in series which would be 14.4V or just about the running voltage of the system.

Anyway, this project will be a few more days before it is done as I still have to cut the orange indicator covers and swap in the Bi-xenon projectors as well.

projector and shrouds
 

This project has been languishing a bit with work going into overdrive.

Well, I had two problems to solve, the baffle control unit touches the housing if mounted the same way as the original unit and I had no way to mount the M3 shroud as it clips on to the front of the projector normally.

So, looking at the OE shroud I thought I might drill out the front and shorten the projector mounting posts to get the projector to sit 1/2 inch further forward.

This was a bit fiddly to do but turned out well I think.

Very long time but nearing completion
 

Here is a picture, two really. Just showing how I cut the turn signal baffle. Trying to make it mimic a post face lift.

Will shoot another pic when they are complete.

Good job. The ring for highbeam isn't round in the picture. It's crooked.

For the last week I have been wondering if I could do something better with the high beam reflector. Thinking I will install another projecter lens and M3 shroud there like this.

This is taking you long enough. :nanana:

Good luck with more crazy retrofitting. :thumbup:

Been too lazy to sell my retrofitted Hella RS6 Bi-xenon projector headlights so far but need to do it soon.

Guilty as charged! Hope to finish soon now. :-)