E89 E89 Z4 halo DIY - possible takers?

fmorelli

Major General
Staff member
Aug 11, 2017
3,102
Virginia
I'm knee deep in too many projects, but just talked to Zaki on Facebook that has "fixed" the strong halo/weak halo setup on the Z4 without spending a gazillion dollars on sending headlights to someone for complete refresh. Basically the parts are $45 and the results look great. He said the headlights come apart with a hair dryer and a bit of patience. They are silicone sealed. Has to go back together with silicone.

I would tackle this but I have way to many parallel projects in flight right now. It would be GREAT if one of the Z4 guys here would sign up to tackle this as a DIY thread, and pave the way with some content on doing this. I have access to the guy that already did it, if questions are necessary. Here's the results and where to buy the rings:

https://www.aliexpress.com/item/32947747858.html?spm=a2g0o.cart.0.0.35493c00sRH3yA&mp=1

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Anyone willing to give this a try and post up some process and photo DIY?

Filippo
 
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fmorelli

Major General
Staff member
Aug 11, 2017
3,102
Virginia
I ordered the lights - cheap. I'd like someone to DIY this with a few photos and pointers. I won't get to that for a while, I'm afraid. I'm already with a backlog of stuff to post that I'm now trying to push out. C'mon somebody get motivated to do this and post about it.

Filippo
 

fmorelli

Major General
Staff member
Aug 11, 2017
3,102
Virginia
Just posting up what Zaki provided me on Facebook. See below.

Filippo

--- cut here ---

So this is my breakdown of the process.
1. Remove the front bumper for ease in unscrewing the headlights themselves.
2. Once headlights are removed get a towel or a thick piece of cloth and put the headlight on it in order to not damage it while moving it around.
3. Use a hairdryer along the outline of the headlight where the silicone is in place, that will be the black plastic section connected to the plastic lens itself. Keep in mind that the silicone is thick and deep you don't worry if it takes time.
4. Make sure you spend a decent amount of time along the outline for the silicone to melt properly or you may damage and crack the plastic when removing it. Also remember to slowly pull it apart, not all at once.
5. Once the plastic lens is off carefully take all the layers of the headlight apart. There are 2 plastic layers inside which hold it together with several plastic components for the projector and signal indicator.
6. Make sure you keep all the components in the right order so you can place them back after taking them apart.
7. Use superglue or double sided tape to stick the LED rings onto the ring outlines around the projectors.
8. Once this is done let it dry for a good 15-30 minutes to be safe.
9. Now you can place all the components back together, keep in mind you'll have to put some of the components back in place before sticking the LED's on or else they don't fit. Don't glue anything until you get the fit right.
10. Once you've done this you can stick the caps back on and make sure to tighten it properly with industrial grade silicone.
11. The LED's have wires connected to them which you connect to the wiring of the cars DRL system. It's fairly obvious to stop, right under the dust cap. Drill a hole in the dust cap to stick the LED wiring through in order for it to reach the cars wiring. Then put silicone to cover the drilled hole with the wire though it.

Enjoy your new DRL's!

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Osiris

Lurker
Sep 19, 2019
24
South Africa
So I did a halo retrofit on my Z4....Results looks amazing but I will never do it again as long as I live. The lights on the Z4 are sealed by the power of grey skull and you basically end up butchering them to get them open :( These are not sealed with Butyl like the E92 its sealed with a glue called perma seal and let me tell you that stuff lives up to its name.

I have retrofitted projectors and angel eyes to many many vehicles and bikes over the years. nothing comes close to the annoyance and difficulty of opening the E89 headlights.

I have a build of this on another forum. will have to find the link if you're interested to see how I did this all.


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Osiris

Lurker
Sep 19, 2019
24
South Africa
I decided to find my DIY and saved all the pics to put up here.

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Roll of Butyl glue I ordered to reseal the headlights with. Don't use silicon because if you need to reopen the headlights again you will kick yourself.
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Blacking the inner chrome bits out.
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I blacked this out too.
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old vs new.
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old vs new closed up.
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Decided to clean up the hazing of the projectors. old...
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Cleaned up like new.
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Nice neat install for the halo power unit.
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fmorelli

Major General
Staff member
Aug 11, 2017
3,102
Virginia
Very nicely done and thank you for sharing the photos. A few questions, if I may:
- do you have a link to the specific halos you used?
- maybe a link to the butyl seal as well?
- any specific guidance on pulling apart the lights? I've done some as well - my worst fight was a 2003 E39 ... turns out the only E39 year which was sealed differently.

Looks fantastic. Thanks!

Filippo
 

Osiris

Lurker
Sep 19, 2019
24
South Africa
Very nicely done and thank you for sharing the photos. A few questions, if I may:
- do you have a link to the specific halos you used?
- maybe a link to the butyl seal as well?
- any specific guidance on pulling apart the lights? I've done some as well - my worst fight was a 2003 E39 ... turns out the only E39 year which was sealed differently.

Looks fantastic. Thanks!

Filippo
Thanks man, appreciate the compliments.

I unfortunately don't have a link to the halos I used, I bought them from a shop here in South Africa called Violet Electronics. But I have seen very similar sets available on ali express. I did this for someone who had an E90 LCI, he ordered the halos off ali express. The wiring harness was horrible and they were not as bright so I would look for the kit that has the same power unit as mine in the photo.

The butyl seal I just bought here: https://www.gluedevil.co.za/products/tapes/butyl-8x8-tape

You need allot of patience and allot of heat! also you need those expanding Pliers the one I arrowed and the tools I circled, the plastic trim tools will also come in handy.

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The best way to do this is put the headlights in the oven and keep an eye on them, I cant remember what temp I put it at as I basically did it by feel, around 110 - 150 Celsius for around 15 - 20mins to get the headlights equally heated. then you need to use a heat gun, a hair dryer wont cut it, not for these headlights! maybe if you lucky and the perma seal wasn't fused by grey skull himself?

Go around the entire headlight with the heatgun and concentrate more on one corner of the headlight and begin pulling and prying till it starts to give way and get the pry tool in there, it will fight you! once its in one side use the heat gun and little bit by little bit push the prytool along while expanding and heating, don't heat too much as the plastic will bubble fast, also don't pull on the light too hard as you will get stress marks.

You will get it open, to give you an idea it took me a total of I think 4 days for this project, I am very OCD, I want stuff to look factory, I don't like wires all over the place and ugly cuts.

you do need to cut the lights as the edge of the halos do collide with the inner housing so get a very small cutting bit for your dremel and cut little by little, this process took me the longest as I didn't want anything to be visible when it was all assembled.
 

Osiris

Lurker
Sep 19, 2019
24
South Africa
These are the cuts, the inner one was difficult to get right due to where it is, your basically cutting that removable plastic shroud. the second cut I did on the other headlight was neater. but regardless you cant see this once all fitted unless you really go close up and look for it.
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fmorelli

Major General
Staff member
Aug 11, 2017
3,102
Virginia
Very nice ... great attention to detail as well, @Osiris. If you happen to see a representative link on Aliexpress, that looks like what you installed, please share. I have a round set which I like as a period correct look, but I have to say these look great. I normally don't like the "make it look like a later model care" thing ... basically screams, "I can't afford a new BMW" to me. But the way you did it, with the black out and such ... really elegant look!

Filippo

p.s. For those in the USA, you can buy Glue Devil directly. There are other choices in the USA as well. The no excuses pick would be the 3M butyl which is about $25 for a roll. For half that, this will do it as well.
 
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