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      11-29-2012, 10:26 AM   #4

Drives: 2012 F30 328i
Join Date: Apr 2010
Location: Brighton, IL

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: