[Mk4 Golf] OEM Xenon Anni Mod - with pics - Audio, Electrics and Lighting - uk-mkivs

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OEM Xenon Anni Mod - with pics



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#1 patchrico

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Posted 03 June 2006 - 04:58 PM

Recently completed an 'Anni mod' to a pair of OEM xenons so thought I would post up some pics.

The glass on the xenons cannot be removed without smashing the lens which is the most alarming thing about doing this mod but once you get over this the rest is fairly straight forward. The other thing is that all the chrome and reflective surfaces are very easy to mark, so as soon as the glass is broken precautions must be taken to prevent this. I used cling film just to stop any particles from touching the chrome. Also when I removed this I used a lens cleaning cloth to gently wipe any 'bloom' away on the chrome. (** CARE 15.06.08 update: If using clingfilm try not to let it 'stick' to the chrome as others have had problems with this. An additional precaution would be to place a cardboard shroud around the edge of the light casing and place the clingfilm across that, Credit to member 'Lim_walk' for that tip).

The replacement glass lens came from some aftermarket units. The glue on these could be softened by heating and came of fairly easy.

Then just needed to rub down the chrome cowling, prime and spray with satin black.

I fixed the glass lens back on with Sikaflex adhesive sealant which does the job very well and because its black, blends in well with the Anni mod and colour of the units.


Chrome cowling taken out

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Chrome cowling rubbed down with 600 - 1200 wet and dry

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Cowling first primed then painted up black

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OEM glass smashed and groove cleaned of old adhesive and remaining glass particles (most difficult part)

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New black cowling on - without glass

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New glass

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Sikaflex adhesive (I had a cartridge of this already that came with some bodykit - but would recommend it for the mod)

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RH unit with glass put back on

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RH close up

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LH close up

Posted Image

 

 

I just painted up the cowling black as it seemed that anything thing more than this was going to be very difficult. For instance masking up any of the main chrome work on the unit would leave marks when it was removed. So I finished up whilst I was still ahead [:)]

See guide/tips further down the post>

 

 

 

 

 


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#2 Gti Fly

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Posted 03 June 2006 - 05:25 PM

Wow stunning!  11 out of 10 for effort mate - very OEM++++


<a href="https://uk-mkivs.net/...d-0-60-569secs/">Click for pics of my car</a>
Shoulda got a 150 tdi - everyone knows they are best..

 


#3 GaryM

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Posted 03 June 2006 - 05:52 PM

Superb Patchrico, quite simply the best mod i've seen to date.
I love the look of the blackened Anniversary lights but also OEM xenons for sheer light output, you've created the perfect headlight in my opinion.


#4 Dubswich

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Posted 04 June 2006 - 10:15 AM

Look really good mate.  I hope to complete mine sometime this week, but they are slightly different to yours.  I will try and post some pics up soon.


 



#5 Carlos

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Posted 04 June 2006 - 12:16 PM

They look cool.... well done!


#6 Satnam

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Posted 04 June 2006 - 01:19 PM

They look f'in awesome [:D] get some pics of them on the car i think there gonna be a must for a lot of people now.. as most people like the anni lamps but also like the light output of the xenons as gary m stated above...

Sat [y]


#7 patchrico

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Posted 04 June 2006 - 02:36 PM

Thanks guys --- the mod was worthwhile in the end, its just the smashing of the xenon glass when they actually look so good just as standard.


Will get them on the car in the next week or two as its in the bodyshop at the minute.


Dubswich - best of luck finishing yours up - looking forward to seeing your pics (with a difference) [:)]



317679852.jpg
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#8 Viperpsych

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Posted 04 June 2006 - 03:56 PM

Looks wicked mate.

Could you not have done the oven trick?

You know when you put the headlight in the oven for a while and prise the glass off.

I'm looking to do this to my xenons if and when i get them.

Very Rare on a Bora though?

Keep up the good work mate.

Dan


#9 Sprog

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Posted 04 June 2006 - 04:03 PM

Mate....they rock!.....you rock!


I was looking at a OEM xenons but didn't want to lose the smoked effect. Am not sure about the whole HID conversion route either!


They look the total t|ts! I think i'll be doing that too I think!



#10 red-jeffers

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Posted 04 June 2006 - 04:23 PM

WELL..................................


What can be said about them bar from total perfection want them badly



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Posted 04 June 2006 - 04:48 PM

eXCELENT bY FAR ONE OF THE BEST HOWTOS WEVE HAD IN A WHILE.... HOWEVERE
i CAN NOPW SEE IT BECOMING MORE EXPENSIVE AS USED HEADLIGHTS GET MORE
POPULAR ON FLEA BAY







damn caps lock





#12 Pat

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Posted 04 June 2006 - 05:00 PM

Superb Patchrico, quite simply the best mod i've seen to date.
I love the look of the blackened Anniversary lights but also OEM xenons for sheer light output, you've created the perfect headlight in my opinion.


Couldn't have said it any better to be honest. I've tried modding headlights in the past and given up. Respec' P [:D]

#13 shiuming

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Posted 04 June 2006 - 05:36 PM

Absolute class [Y][Y][Y]


Don't forget to transfer over your sidelights.



#14 Dubswich

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Posted 05 June 2006 - 04:45 AM

Hey Patrick,  Finally got some pics together, although they were taken by my phone !!


Very similar to yours, I have done the cowling in a metallic grey (as opposed to black) and deepened the orange of the indicators, with some translucent glass paint.  My other lights turned up this morning, so I will be baking them later to see if I can get the damn lenses off !!!


Sorry for the hijack, but couldn't let you steal 'all' the limelight !!!  [;)]


Posted Image


Posted Image



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Posted 05 June 2006 - 05:35 AM

can you guys do a set for me!

#16 Pricey

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Posted 05 June 2006 - 05:47 AM

Top marks guys, that mod looks great! [Y]



I should have the same effect once I get a HID kit for my smoked angel eyes [:D]





#17 RAR1F

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Posted 05 June 2006 - 11:06 AM

Well done, respect to anyone who goes the distance, time and money to get the look their after! What was the total cost of the mod if you don't mind? Think you should start churin em out for a living am sure they'll go like hot cakes!!!


Keep up the good work!



#18 Dubswich

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Posted 06 June 2006 - 11:00 AM

Well done, respect to anyone who goes the distance, time and money to get the look their after! What was the total cost of the mod if you don't mind? Think you should start churin em out for a living am sure they'll go like hot cakes!!!


Keep up the good work!



I should let Patrichio answer since it is his thread, but, for my own set:


Headlight units - 72


Ballasts - 72


Bulbs - All - c50


2nd set of lights, for the lenses 20


10-12 pin adapters DIY - 33


Paint - 4.99


Glue - 8 - Evo Stik shok resistant stuff in a mastic tube.


other items - c40 (lug repair kit, etc).


All in with all the postage etc, I would say about 300 mark.  So not cheap, but well worth it, IMO.


As for selling them, I think not, too much hard work !!!!  I might do my other reflector lights though, so watch the classifieds !!! I just need a pair of lenses.



#19 patchrico

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Posted 06 June 2006 - 05:35 PM

Thanks again for all the positive comments.

With regard to the cost, I had a couple of mods going on with these lights -- one was to get them working off the Hella ballasts I already had installed and the other was the Anni Mod.

I put together a dedicated loom with relay etc to fire up the OEM xenons- this worked out very cheap especially as I got the brand new xenon units for £125.

The Anni Mod also did not cost much as I had everything already in the 'shed' apart from the satin black paint. -- I actually used:


  • Glass lens (from old aftermarket headlights I already had spare.The glass was actually exactly the same as the OEM and was a perfect fit) 

  • Grey etch primer - (from Halfords - put on about 3 coats)

  • Satin Black paint (from Halfords - bought 2 cans and swaped over to the second can just before the first one run out - just to stop any splatter from the aerosol spray - put on about 4 coats.

  • Wet & Dry abrasive paper (already had some 600, 1000, and 1200 so used it all on the chrome cowling - before priming)

  • Sikaflex adhesive (did initially buy some other type of sealant but switched over to the Sikaflex - which was a good decision as I was pleased with the results). You can put a bead of this around the groove and press in the glass (secure very tightly with duct tape until dry) - when set you can then put some more around the edge. The Sikaflex is workable both when wet and when its dry (can be cut back) so you can get a very good finish. 

  • Some duct tape to help secure the glass on whilst the Sikaflex set.

  • Cling film. (** CARE update: If using clingfilm try not to let it 'stick' to
    the chrome as others have had problems with this. An additional
    precaution would be to place a cardboard shroud around the edge of the
    light casing and place the clingfilm across that, Credit to member 'Lim_walk' for that tip).

  • Specialised lens cleaning cloth (the type you get with expensive sunglasses etc) - used this as it did not mark the chrome.

  • Silicone adhesive - I just used this to fix in the cowling (it has 3 lugs) - the Sikaflex was used once the cowling was set in.

  • Also got through about 3-4 pairs of latex gloves that were used each time I had to work near the chrome surfaces.


As for tools:


  • Oven (to get aftermarket glass lenses off) -- this may work on OEM units or you may need a Dremmel to get the glass out intact [This is for the 'replacement' glass' only --- you cannot get the OEM xenon glass out with heat)

  • Hammer  - to smash the Xenon glass (best to do this over an old sheet and even place some of the sheet over the glass as you do this as the glass goes everywhere and it is very sharp)

  • Some small brushes to continually brush out all debris from the units - you do not want anything left inside once the glass is sealed back on).

  • Needle nose pliers, stanley knife and screwdriver (get one screwdriver with a tip the same width as the groove in the headlight unit) - all used to clean out the groove of glass and old adhesive). TIP - before you smash the glass, use a stanley knife to cut into the existing sealant. Just run the knife around the edge of the unit - this will help to release the glass fragments that are left behind.

  • I also had some Isopropyl Alcohol which I used to clean everything up (only the plastic unit, the new glass and the actual projector lens surface, not the chrome- before sticking on the new glass).


Can't remember anything else - so good luck to anyone else doing this[:P]

Absolute class [Y][Y][Y]

Don't forget to transfer over your sidelights.

Thats right mate - I will get those PIAA's transferred over ( I wired in the correct bulb holder and connections in paralell with the type that comes with the xenon units - then can swap between the two if needbe)

** Dubswich -- well done mate, I like what you have done with yours -- You are welcome to join in the thread matey (get that new glass on [:D])

Patrick

 

** Lim_Walk's  -- clingfilm / cardboard shroud pic:

Posted Image


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#20

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Posted 07 June 2006 - 04:40 PM

does anyone know where i can get the ballasts/power packs for the xenon headlights apart from ebay? how much am i looking at?

#21 patchrico

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Posted 08 June 2006 - 09:10 AM

does anyone know where i can get the ballasts/power packs for the xenon headlights apart from ebay? how much am i looking at?


If you are after OEM ballasts for either pre or post 03 xenons - then German Ebay is probably the best place to pick them up at a reasonable price.



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Build Thread / Anthracite / R Line front & modded R32 rear bumpers / Oettinger side skirts / shaved rear door handles with power open / half cup front handles / custom trimmed leather seats / black & grey alcantara interior / custom binnacle / carbon centre console & dash end caps / Carbon Kevlar Cluster case & colour mfa / Audi RS4 steering wheel with engine start button / SFS Supersize TIP / Bosch 440cc Injectors / 3" Downpipe / 3" Alloy MAF housing / SS Custom Airbox / Pro Alloy FMIC / 034 Motorsport Inlet Manifold and fuel rail / Ported Exhaust Manifold / Moroso Catch Can / Silver Project Top Mounts / Vibratechnics engine mounts / Poly bushed suspension / Front & Rear Brace / Bilstein PSS9s / BBS CH custom finish / BBS IMPUL / AP Racing 6 pot calipers / Tarox rears / VR6 clutch G60 SMF / TT cast wishbones & Hubs / R32 steering rack / H&R front Nuespeed rear ARBs / R32 power fold mirrors mod / OEM Xenon Joey mod / BBT K300 turbo 303BHP 324Ft.lbs
 

 


#22 Dubswich

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Posted 08 June 2006 - 11:57 AM

does anyone know where i can get the ballasts/power packs for the xenon headlights apart from ebay? how much am i looking at?


If you are after OEM ballasts for either pre or post 03 xenons - then German Ebay is probably the best place to pick them up at a reasonable price.



You will need to do a search for "xenon steuergerat" on EBAY.DE


Best of luck mate, there are usually tons on there, there are also loads on the US ebay.com, but obviously shipping takes a while and they are not as reasonably priced as the German site.


Apart from Ebay, you could try scrap yards, but when I tried they wanted stupid money, so it was back to good old Ebay !!!  Bear in mind, ANY ballasts will do, provided they dont have built in igniters.  I think the BMW E46 ones are the same Bosch type as the VW/Audi ones.  But theoretically you could use any HID Ballasts.  Patrichio, has used a pair of aftermarket jobbies, which is also an option and they would come with all the wiring harness you need, but not the cheapest option.


Try a place called "motors in motion, VW dismantlers" which is where I got mine.  Tel No - 01909 531537.  Mobile - 07771 785268 / 07780 941611.


As for the price mate.  I was expecting to pay anything upto 150 for a second hand pair, but actually got some for 72 inc the wiring harness (bargain !!).  New retro kits will set you back double that price. (300ish)



#23

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Posted 08 June 2006 - 04:48 PM


does anyone know where i can get the ballasts/power packs for the xenon headlights apart from ebay? how much am i looking at?


If you are after OEM ballasts for either pre or post 03 xenons - then German Ebay is probably the best place to pick them up at a reasonable price.



You will need to do a search for "xenon steuergerat" on EBAY.DE


Best of luck mate, there are usually tons on there, there are also loads on the US ebay.com, but obviously shipping takes a while and they are not as reasonably priced as the German site.


Apart from Ebay, you could try scrap yards, but when I tried they wanted stupid money, so it was back to good old Ebay !!!  Bear in mind, ANY ballasts will do, provided they dont have built in igniters.  I think the BMW E46 ones are the same Bosch type as the VW/Audi ones.  But theoretically you could use any HID Ballasts.  Patrichio, has used a pair of aftermarket jobbies, which is also an option and they would come with all the wiring harness you need, but not the cheapest option.


Try a place called "motors in motion, VW dismantlers" which is where I got mine.  Tel No - 01909 531537.  Mobile - 07771 785268 / 07780 941611.


As for the price mate.  I was expecting to pay anything upto 150 for a second hand pair, but actually got some for 72 inc the wiring harness (bargain !!).  New retro kits will set you back double that price. (300ish)



Thanks for the helpful advice really appreciate it. iv already got 1 passenger side headlight with the ballast on the back and bulbs. If i buy the ballast from ebay.com or .de i can then put it on either headlight or is it different for Leftside headlamp and right side headlamp? Iv got the other headlamp with no ballast can i put a BMW e46 ballast on that?



#24 hz2921

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Posted 08 June 2006 - 05:05 PM

Pat, what can i say, i havnt been on the forum for a few weeks as ive been building my garage, but what a good start!!!!!, the lights look wicked!!!, sheer class!!!, once ive finished my garage i,ll set to work on mine!!!


Zak[:D]



#25 Sem

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Posted 08 June 2006 - 05:11 PM

Wow! They look amazing [:o] Top marks from me and [Y] for having the balls to smash lenses on a set of OEM xenons!

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Posted 08 June 2006 - 07:07 PM

Thats balls smashing the  glass on oem Xenons



#27 patchrico

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Posted 08 June 2006 - 08:58 PM

Pat, what can i say, i havnt been on the forum for a few weeks as ive been building my garage, but what a good start!!!!!, the lights look wicked!!!, sheer class!!!, once ive finished my garage i,ll set to work on mine!!!


Zak[:D]



Hi yer Zak -- I wondered what had happened to yours after having spoken about doing this a while back - get yours done and join the club.



317679852.jpg
Build Thread / Anthracite / R Line front & modded R32 rear bumpers / Oettinger side skirts / shaved rear door handles with power open / half cup front handles / custom trimmed leather seats / black & grey alcantara interior / custom binnacle / carbon centre console & dash end caps / Carbon Kevlar Cluster case & colour mfa / Audi RS4 steering wheel with engine start button / SFS Supersize TIP / Bosch 440cc Injectors / 3" Downpipe / 3" Alloy MAF housing / SS Custom Airbox / Pro Alloy FMIC / 034 Motorsport Inlet Manifold and fuel rail / Ported Exhaust Manifold / Moroso Catch Can / Silver Project Top Mounts / Vibratechnics engine mounts / Poly bushed suspension / Front & Rear Brace / Bilstein PSS9s / BBS CH custom finish / BBS IMPUL / AP Racing 6 pot calipers / Tarox rears / VR6 clutch G60 SMF / TT cast wishbones & Hubs / R32 steering rack / H&R front Nuespeed rear ARBs / R32 power fold mirrors mod / OEM Xenon Joey mod / BBT K300 turbo 303BHP 324Ft.lbs
 

 


#28 patchrico

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Posted 08 June 2006 - 09:01 PM

Wow! They look amazing [:o] Top marks from me and [Y] for having the balls to smash lenses on a set of OEM xenons!


 


Man - I used a hammer rather than my B**** [:P]



317679852.jpg
Build Thread / Anthracite / R Line front & modded R32 rear bumpers / Oettinger side skirts / shaved rear door handles with power open / half cup front handles / custom trimmed leather seats / black & grey alcantara interior / custom binnacle / carbon centre console & dash end caps / Carbon Kevlar Cluster case & colour mfa / Audi RS4 steering wheel with engine start button / SFS Supersize TIP / Bosch 440cc Injectors / 3" Downpipe / 3" Alloy MAF housing / SS Custom Airbox / Pro Alloy FMIC / 034 Motorsport Inlet Manifold and fuel rail / Ported Exhaust Manifold / Moroso Catch Can / Silver Project Top Mounts / Vibratechnics engine mounts / Poly bushed suspension / Front & Rear Brace / Bilstein PSS9s / BBS CH custom finish / BBS IMPUL / AP Racing 6 pot calipers / Tarox rears / VR6 clutch G60 SMF / TT cast wishbones & Hubs / R32 steering rack / H&R front Nuespeed rear ARBs / R32 power fold mirrors mod / OEM Xenon Joey mod / BBT K300 turbo 303BHP 324Ft.lbs
 

 


#29 Cat1.4

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Posted 08 June 2006 - 09:47 PM

Wow, they look brilliant! I wondered when somebody would get round to 'Joey'ing a set of Xenons [:P]

Now all we need are some pics on the car!


#30 Andrew

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Posted 10 June 2006 - 04:27 AM

They look excellent. 


You should start making more sets and selling them on mate, you would make some decent money on ebay.







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