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How I converted Depo Headlights to Xenon

Old Jun 17, 2007 | 05:55 PM
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How I converted Depo Headlights to Xenon

The Depo units need to come apart to remove the substandard projector lens / bulb holder assembly. This sounds weird, but you bake the headlight assembly in the oven to soften the gray putty-like adhesive that is used to attach the front clear headlight cover onto the unit. 10 minutes at the lowest setting your oven has, 200 degrees for me. Even after softening the putty sealant, the clear lens must be pried out with a lot of force, I used an old butter knife and a flat-blade screwdriver. Once apart, the old projector lens assembly is removed (it is a 3-inch diameter glass lens in a metal holder) I purchased a pair of BMW X5 projector lens / xenon bulb / ballast units used on Ebay for $200. The BMW projector lenses cast a much more even, accurate light pattern with a nice, sharp cutoff. You will have to drill new pilot holes into the Depo unit, as the BMW projector lens assembly has a different bolt pattern. Make sure the new lens is oriented in the same plane and position as the old lens when the projectors are screwed into place, you don't want your beams pointed at an odd angle. When the BMW projector lenses have been retrofitted into the Depo assembly, put the headlight assembly back into the oven to soften the adhesive again; this will be neccessary to affix the front headlight covers back in place. Make sure to remove the xenon bulbs before heating! After re-installing the headlight cover, run a bead of silicone sealant all the way around the cover to ensure a good seal. Install the xenon bulbs, and match up the three wires in the stock low beam harness to the three wires on each xenon ballast, and plug the ballast connectors to the bulbs. You will then want to mount each ballast ( I screwed each ballast to the back of the rear bulb cover on the Depo assembly.) This yields a much better, brighter light pattern than stock M-B Xenons, and infinitely more light than stock Depo units or M-B factory halogens. This project took me about 4 leisurely hours. You also need six beers, +-a beer or two depending on your weight .


Last edited by foreyes; Jun 17, 2007 at 06:05 PM.
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Old Jun 17, 2007 | 06:27 PM
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I did same using E55 bixenon projectors. Good job!
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Old Jun 17, 2007 | 09:36 PM
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Cut them on so we can see what they look like!
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