[s-cars] TT HID retrofit into URS

[McCall, Randy]

Paul Dooley wrote:

>> As the end of the year comes, I find myself rereading old s-car email

>> and figuring out if there will ever be any grip on the slippery slope

>> or not (I think not).  I'm intrigued by the idea of retrofitting some

>> Audi TT HID low beam projectors into my Euro S6 headlights, but I 
>> can't find any reference to the exact year/part numbers of TT 
>> headlights I'm looking for.  So, to those that have already done so, 
>> do you have any part numbers?  I believe Fred Munro has done this as 
>> well as Mark Strangeways and I think Dave Forgie while Igor Kessel 
>> use some Euro 740i lights.
>>
>> Some how about some part numbers, years of potential donor cars, and 
>> any other advice you can throw out at us.
>>
>> TIA<
>>
>> Paul Dooley
>> 95 S6

I retrofitted a set of TT HID's into my S6 buckets, but it in retrospect
it wasn't simple....nor all that cheap for that matter.  Sorry, but no
idea what year they came from.

I bought a complete set of projectors, ballasts, ignitors, and bulbs off
of flea bay for around $200, then bought some steel brackets off of
Corey from Edmonton (miniman on AW) who had some made up for the S4's.
Because of the different bucket dimensions I had to do some
customization on both the bracket exterior and the tab area of the TT
reflectors to make them fit into the S6 buckets. Lots of trial and error
getting that correct! (but I do have a pattern if someone wants it!)  I
used some cut-off, long US-threaded bolts with two lock nuts to sandwich
the brackets (and for aim adjusting), redrilled the reflectors and glued
the allthread in for mounting posts; probably 2.5" or so long.  The
ignitors with the high voltage wiring are fairly large potted devices
that I mounted to the back sides of the new brackets and which reside
inside the buckets; I mounted the actual ballasts which were missing the
weather boots in a new sheet metal box I made and ran the thin guage
wires from the ballasts to the ignitors through the back of the access
cover with grommets. With the wiring running through the covers, the
cover stay's in the car when the headlight is removed. However, the
ignitor has a three-pin plug rectangular plug that allows everything to
be seperated. The ballast and relay box resides on a set of brackets I
made that rest just above the ABS unit, and under the hood strut when
closed. I just couldn't find a good place to put the ballasts that would
have been weather proof, and I did not have the weatherproof covers for
them that they look designed for. Everythings tucked in to the box now
and wire loomed and pretty much weather proof.  I also added relay's for
everything - definitely overkill, but I had the room and just took the
plunge.

Topped it all off with Euro HID lenses that were quite expensive, but in
for a penny, in for a pound...  I've had to go back in, take it all
apart, and adjust the relationship between highs and lows for beam
concentricity, but I've gotten it dialed in very nicely now.

The outcome is that the light is awesome - comparable to my wife's
allroad, just with out the self leveling adjustors. No more of those
scary nights driving the back roads of the Willamette valley in a
downpour wondering if that's really the fog line you see dimly in the
stock projector light.... Haven't put in higher wattage highs - I have
the relay's, but I'd probably melt the plastic reflectors.  If only I
had the Euro versions...  

-Randy

'91 200 20V with great lights - relayed Euro's and 80/100's
'95.5 S6 with TT HIDs
'01 Allroad