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BoulderC30s Volvo C30 Halogen->D2S HID retrofit

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  • BoulderC30s Volvo C30 Halogen->D2S HID retrofit

    Hello world!
    Some photos of the progress on my 2009 Volvo C30 headlight retrofit.

    full build of the car on Instagram: @boulderC30

    Stock headlight. Many rock craters from about ~100k miles. Styling needs some refreshing to match the car, plus the halogen output is just terrible.





    removed much of the internals to get the clear plastic headlight lens cover off


    little bit of heat, razor blade and a flathead to pry this guy off


    closeup


    arbon fiber wrap the “chrome” looking shrouding pieces




    wetsanding begins on plastic cover
    went through about 5-6 different grits from I think 500 up to 2000


    clearcoat applied. see the orange peel effect?


    after polishing by machine and by hand. used Adams polishes brand , WOW.


    very very slight tint on the orange reflector. just enough for the detail oriented person to tell its different.


    step 1 of this reno complete! check this baby out



    now onto the lighting hardware...

    Retro-Quik “E46” Morimoto D2S 4.0 kit.


    stock Volvo halogen projector vs Morimoto 4.0


    uh-oh, it doesnt fit! no biggie. time to pull out the dremel.


    not pretty but it fits.








    Here’s how its all connected.
    That little black box with the ground cable is an SKBOWE PWM filter. courtesy of www.skbowe.com, good work figuring that stuff out man! Much appreciated!



    dang that cutoff is wild!


    second to last step, needs to be aimed!


    last step, need to mount both the ballast and skbowe inside he wheel well!


    Thanks for looking!






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  • #2
    Nice work. Very clean & shiny lens afterwards. You might want to protect your hard work with a 40mil clear lens film.
    Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

    3-way quad wiring; foreground limiter; squirrel finder;

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    • #3
      Originally posted by satrya
      Nice work. Very clean & shiny lens afterwards. You might want to protect your hard work with a 40mil clear lens film.
      thanks man! good idea on the film... I’ll get around to that come spring.


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      • #4
        Nice job on the retrofit!

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        • #5
          thanks gold94corolla!

          got around to aiming them by eye last night. need to look up the proper way to aim them though, they might be a little too high, and are definitely off on L/R.
          When I am further away from a wall, the notches are closer together than when I am right up against it.






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          • #6
            Good work!

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            • #7
              thanks guys!
              I am looking for a recommendation on sealed LED fog lights. I see the universal morimoto xb ones, just wondering what else is out there, or if theres other lighting shop websites you guys use? Thanks


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              • #8
                Originally posted by boulderc30 View Post
                When I am further away from a wall, the notches are closer together than when I am right up against it.
                I think erring on that side is better than having the elbows get farther apart as the wall gets farther. This is because each projector's beam gets weaker as it extends farther out, leaving a narrowing column effect. When the projectors are completely parallel or slightly yaw inwards to each other, the weakening beam can reinforce each other a bit more to help maximize distance reach at the car's centerline.
                Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

                3-way quad wiring; foreground limiter; squirrel finder;

                Comment


                • #9
                  Originally posted by satrya View Post
                  I think erring on that side is better than having the elbows get farther apart as the wall gets farther. This is because each projector's beam gets weaker as it extends farther out, leaving a narrowing column effect. When the projectors are completely parallel or slightly yaw inwards to each other, the weakening beam can reinforce each other a bit more to help maximize distance reach at the car's centerline.
                  Oh, good point. I think thats a good thing to keep in consideration.. It seems ideal to have each projector pointing slightly inwards, like a V but very very slight.

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                  • #10
                    Originally posted by boulderc30 View Post
                    like a V but very very slight.
                    very very very slight
                    Jul 2012 ROTM (3-way quad headlight) ; Sep 2015 ROTM (custom muli-lens 7" fogs)

                    3-way quad wiring; foreground limiter; squirrel finder;

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                    • #11
                      help! can someone point out how to pop out these wires from the plastic clip, and reattach? I need to pass them through a rubber seal on the headlight door




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                      • #12
                        just kidding, used a paper clip...


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                        • #13
                          modifying the door to make the seal fit.

















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                          • #14
                            Helped a friend paint his headlights the other day. what do you guys think?
                            He needs an LED in the turn signal area. It was his idea to paint the reflector, not mine haha.



                            heres the lights beforehand










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                            • #15
                              should have painted the high beam reflector too while he was at it lol

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