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      11-29-2012, 09:26 AM   #4
GenePoole
Lieutenant
9

 
Drives: '06 E90 330i
Join Date: Apr 2010
Location: Brighton, IL


Posts: 537
iTrader: (0)

Plug it all in to make sure it all works (it does!):




The D2S bulb with it's connector is slightly taller that the D1S. That might be a problem




A zip-tie should take up the slack:




Acceptable fit:




Now I have to seal up the box to keep moisture out. Time for a little woodworking:




A little sanding and it fits snugly with the original o-ring:




Now to make a complete cap:




Epoxy: the other best friend of a hobbyist:




Clean up the excess:




Now that it's set, drill a hole for the wires (I'll plug this with RTV silicone once it's installed):




A little more sanding:




And a coat of paint to seal it:




A metal strap and it fits nicely in the original slot. Now to put it all back together: