RWLib3

<img src="http://pictureposter.audiworld.com/79099/nolights.jpg">

Not really...just removed them to do a couple mods. =)

First I removed the orange lenses...

<img src="http://pictureposter.audiworld.com/79099/clear.jpg">

Then I retro'd a set of OEM HID Ballasts and Projectors into the OEM Halogen headlight. Can't wait to see the difference tonight and so I can adjust the levels so I dont blind anyone =)

<img src="http://pictureposter.audiworld.com/79099/hidvshal.jpg">
<img src="http://pictureposter.audiworld.com/79099/hid.1.jpg">

4Driver4

How did you get the housings apart without damaging them?

When I tore some HID units apart to "harvest" the projectors for my urS6 I destroyed the housings getting them apart.

RWLib3

Had some of the black sealant to clean up, threw em back in the oven to put them back together.

4Driver4

Huge b@lls to put the $$headlights$$ in the oven. Good trick though.

kkemp

Xenon projectors and halogen bulbs have dramatically different performance characteristics. If you just cut the back out of the halogen housing and popped a xenon projector in there, you'll basically never be able to get the lights aimed properly. They'll be scattering light inappropriately, either not being as effective in lighting the road, dazzling other drivers, or both.

Sorry to be harsh but mods like this (if in fact that's what you did) are what give HIDs a bad name and have the federal governtment considering banning them.

TeddyBGame

Ever since I did my OEM HID upgrade (see sig for details)...I often wondered if the inner housings of these headlights (HID vs. Halogen) were interchangable (historical reference to Eli Whitney...for those history buffs of firearms...and the inventor of the cotton gin..and a local Boston native in the late 18th century....but I digress). I have a couple sets of halogen housings in my attic that I've been planning on experimenting with....but have been busy with other mods (see my sig). I was able to ****** up a mint pair of E-code halogen housings (DRLs, clear corner, etc) for my 2001 A6 2.8....for $100. So I always wanted to see if I could just add the HID projectors, ballasts...and just make them work....but more on that later (see below).

Hella is the OEM supplier of the headlight housings for the C5 A6/allroad/S6/RS6 etc. Based on your pictures, it looks like the halogen reflector and the HID projector share the same mount points for the internal housing. You probably used a pair of needle-nose pliers or a nut driver to get them out....either way...you'd need some small hands to do the job (reference to Austin Powers "Carnies....smaaaulllll hands". Ha!)

While the inner housing of the HID housing has:

A) HID projector/optics for a D2S bulb vs. a Halogen reflector
B) Auto-leveling motor linked to sensors in the rear of the vehicle
C) A different black plastic rear cover with specific openings for the HID/ballast wiring. (Ryan: I assume this is what you used the black epoxy for? Can you clarify? I only hope that your headlights don't suffer from internal condensation as a result of this...as the rear of the headlights have specific "exhaust" ports for channeling any humidity out of the housing; only time will tell. Please keep us posted.)
D) The passenger side (for US-based left-hand drive models) projector has a slightly different cut-off angle, as it is designed to provide more light onto the sidewalk area (for spotting deer etc.) while not blinding oncoming traffic via the drivers' side.
(Ryan: How were you able to determine which projector was for the drivers' side vs. the passenger side? Please...share your knowledge.)

So here's a laundry list of what parts you'll need to do this:
1) Original OEM halogen housings (daaaaaahhhhh!)
2) HID projectors (E-code or DOT/US); only the C5 A6 projectors will fit. Also, if you have a 2002-2004...then you could probably do this same mode to add the bi-xenon projectors. Cost: $100-$150 via ebay; just make sure they come with the plastic bulb holders. FYI - the C5 A6 HID projectors are the most commonly used for HID retrofit projects for the "ricey" Honda Civic-types.
3) OEM Ballasts and associated wiring: It is best if you find some that are from a wrecked/broken/damaged A6 housing, as the length of the ballast wiring will be an ideal fitment and will probably include the unique black plastic covers to make this an easier install. Cost: $150-$250 via ebay.
4) D2S HID bulbs: Go for a new pair, so you have equal "burn-in" rates for both bulbs. Cost: $100/pair via ebay...or $300/pair from dealer.
5) Wiring: The only wiring you'd need to do is to run the two wires from the HID ballast into the internal wiring connector to provide power/ground to power the ballast. I have proven that the wiring from a non-HID equipped A6 is exactly the same for one that came with HID from the factory. Therefore, you shouldn't be worried about "frying" your wiring etc as a result of this mod (FYI - mine has been working for 2.5 years. Of course, your mileage may vary...standard disclaimer stuff..etc.)

Given all of the parts needed, you'd probably need to spend about $400-$500 for these parts. Then comes the installation (Ryan: Can you provide some more insight into how you did yours?).

The other option, would be to just purchase a set of used HID housings from ebay and spend about $200-$250 per housing. Which is what I did (again, see my sig for all the details you could ever need).

Just some thoughts. Just my .02. I hope this helps those who want to add HID..without adding a "ricey" aftermarket kit.

-ted (Go Celtics!!)

4Driver4

<center><img src="http://pictureposter.audiworld.com/79099/hidvshal.jpg"></center><p>

RWLib3

I'll need to go thru your laundry list more thoroughly when I have the time. (later tonight)

Yes they are OEM A6 Ballasts and projectors, but unfortunately the projector mounting posts are different. They're close..but definately different. There are 3 connection points for the inner reflectors and it pops right out. Makes removing the projector a hell of alot easier. I'll explain in more detail later. Wishing now I took pics though!

The ballasts I bought came with the original backplate to the headlight so there was no cutting invlolved. I did have to drill a small hole to run the wiring from the H1 plugs (cut) to the 9006 connector on the ballast. Filled that with some black silicone to prevent the condensation factor (hopefully)

<img src="http://pictureposter.audiworld.com/79099/hid.jpg">

I'll hopefully take some pics tonight of the beams.

RWLib3

and its Rich not Ryan =)

kpereyra

See my sig for an example. Looks good though.