straight6pwr said:

the real bees knees would be an entire 3D printed headlight housing that could hold one of the larger, better bixenon projectors.  remove the glass and inner shroud from your original headlight, attached it to the 3D printed housing, and mount it into the headlight frames. as you found, the housing is too small to hold anything larger than the H1 mini projectors, which are an upgrade from stock lights, but far from the best performance bixenon. 

That’s a super interesting concept. It would be an intense project. 
 

I’ve had some people ask about the led bi xenon projectors and I have to explain that I don’t think people understand how small these buckets are.

And then there’s the Bosch smileys. I printed the first one to test fit last night but that bucket is tiny.

KaiserRolls said:

I don’t know anything about headlights but I know I can’t see shit at night. 
 

really cool stuff man

Ha! 
 

This all started when I drove through the night back from Utah. And all I could think about was that if there’s a deer 50’ in front of me I’m not going to see it.

really cool stuff man

straight6pwr said:

very awesome! there have been multiple attempts at prototypes for these but i've never seen any sold on the market. 

Well, thank you. I know Squared Motorwerks used to offer a similar thing, but from what I can see he's no longer doing it and has been MIA for a few years. 

It was interesting diving deeper than I thought I would have into how to improve the headlights and not really finding any great solutions out there. Lots of posts where one person says "this bulb changed my life!" and the next says it's garbage.

YoungCR said:

Would you be interested in developing a E32/E34 version? 

Yeah! I have someone sending me their Depos for an e34 to check if they are the same as the e30s. Depending what you have, if it’s like the e30 Ellipsoid, what I have might already fit.

m42b32 said:

Looks like a really nice solution!! Fully sealed up when it's installed? 

Yup. The lip has a foam seal in it similar to the OEM bucket. And then the Ellipsoid adapters uses a second screw that goes in the top of the factory housing and that screw has an o-ring on it to seal it. the only sealant you should have to use it a small bead around the bi-xenon connector where it passes through the backside of the Morimoto housing.

patsbimmer1 said:

This is awesome!  

Thank you! It has been a super fun project.