Xenon Lamp System Install
Well It's been a while, I've been slowly gathering parts and knowledge to try and install a Xenon HID lamp system in the car(VW Golf IV).
The first thing I purchased was an aftermarket HID kit from Autolamps Online through a group buy on VW Vortex. I received the kit and was going to install it into the the standard NA(North American) housing. Around the same time I replaced some relays on a vehicle that were faulty (not the VW). The relays were damaged by water. The HID kit comes with a relay harness.
I also read a lot on HID systems being put into Halogen bulb housing that were blinding people.
The combination of relays and Halogen housing made me shelve the idea of installing this kit.
I ordered some FETs to replace the relays from Digikey and made a FET switch. The switch seemed to work ok.
In October 2002 I called PG Performance about the hella triple round lighting kit these are based on their projector lighting system. It was decided to use Hella since I found some info at http://faq.auto.light.tripod.com/hella-headlight-units.htm on how to modify the projectors. Lucky me, PG Performance was having a thanksgiving sale (20% off). I also picked up the Rheostat to control the levelling feature of these housings.
The sheilds were modified.
A piece of steel was brazed onto the existing sheilds, seemed like the easiest thing to do for me.
Some brackets were made to hold the ballasts, the aim of this install was to make it easy install and unobstructive for maintenace purposes (nothing getting in the way if service is required to the front end).
All wiring was covered with wire-loom to prevent any chaffing if they rubbed anywhere, the FET harness was also wrapped with hockey(cloth) tape.
Something I did during this install was to put the nuts and bolts into seperate ziploc bags for the parts taken off (bumper cover, bumper, lights). This made re-assembly a little easier since the fasteners weren't kicked all over the garage floor, lost, or mixed up.
A Hella headlamp washing kit has also been ordered from PG Performance to supplement this lighting setup. Page will be modified to reflect that.
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