B6 Projector Upgrade

[kamold]

So my headlights got so bad it was dangerous to drive at night.
I'd already replaced the stock D1S with new genuine Philips Xtreme Vision so I knew it wasn't the bulbs.

After some research I discovered that the Valeo projectors inside the headlights are known for burning out at the back, causing light output to drop.

I bought a set of lightly damaged headlights from a wreck and some plastic welding tools to repair the broken tabs.



Bought a set of Aharon Optimus NT projectors for Right Hand Drive (also known as Left Hand Traffic) from Retrofit lab:

Aharon Optimus NT - Bi-xenon projectors Hella design



Cut the headlights open with a dremel in order to access the projector assemblies within:


Needed new brackets to mount the new projectors as they are slightly fatter and deeper:


Sealed up the headlights with plastic weld staples and Sikaflex 227:


Original low beam:


Upgraded low beam:


Cutoff:


Original High beam:


Upgraded high beam:





Inner shrouds:
TAOCHIS Car Styling Shrouds Mask for 3.0 inch HELLA 3R G5 Koito Q5 Bi Xenon Projector Lens Retrofit Head Light Volkswagen Tiguan on AliExpress
Brackets:
TAOCHIS Adapter frame Head light for VW Volkswagen Magotan Adaptive Frontlighting System AFS Hella 3R G5 Projector lens-in Car Light Accessories from Automobiles & Motorcycles on AliExpress

[Ozsko]

I bet that was a satisfying result. BTW check the time stamp on your edit 03:12 PM

[kamold]

Yeah super satisfied with the result. I really appreciate being able to see where I'm going in the dark...
Not sure I understand the edit comment?

[3C4M Guy]

Well done. Your ability to do upgrades never ceases to amaze me. I want to be around when you eventually sell your car!

[kamold]

Never selling it. Just upgrading.
Actually got it out in the dark tonight and it's sooooo much better.
Looking forward to a proper night drive in the country now.

[kamold]

A little darker

[kamold]

Shutters open for some high beaming

[Passat my07]

That’s a fantastic upgrade!
Do the new lights come with the shutter motor? Mine is faulty on one light.

[kamold]

That’s a fantastic upgrade!
Do the new lights come with the shutter motor? Mine is faulty on one light.

Yes the projectors have the shutter motors in them.

[dArK5HaD0w]

nice work - as always
that is a huge difference there.

[Thanhnos]

Nice job Kamold! This mod made a huge difference, the original lights seem pretty weak in comparison.

[IanPGonzaga]

i think you need to show their performance in a real life situation (city enviroment and low light, road trip, rural) to really get the point across how much of a visual upgrade this is!

[kamold]

It's always hard to see in a few pics.
You're right in practice the effect is really fantastic.
I don't have a GoPro or similar otherwise I'd try and take a video.

[pnoake]

Nice job, but a lot of work for mere mortals. Did you consider a plug and play replacement with an LED aftermarket set of headlamps from our Ali friends like these?

Online Shop Head Lamp For Car VW Passat B7 2012-2016 Magotan Headlights Fog Lights Daytime Running Lights DRL H7 LED Bi Xenon Bulb Accessory | Aliexpress Mobile




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[kamold]

Led has less light output than hid.
Also B7 headlight assemblies don't fit b6