Audi A4 Valeo Headlight Projector Bracket (B6)

thingiverse

A common problem with projectors in OEM Valeo Bixenon housings on B6 A4s is that the reflector bowl can become scorched, leading to reduced light output. Instead of replacing the entire headlight housing only to see the issue recur, one can use this bracket to swap out the projector itself with Koito Q5-r Replica projectors or similar D1S bixenon projectors. This also allows you to retain the original ballast and bulb type (D1S) as well, helping keep costs down. This modification is outlined in the Audizine thread. The credit for the original bracket goes to the OP of the thread who posted the DWG file. I simply added mounting holes for the projector that were missing and created an STL so it could be 3D printed. Avoid using PLA material for this bracket, as the inside of the headlight housing can get quite hot, and any warping of the part will cause issues with beam alignment. I chose a Carbon Fiber Nylon material for good stiffness and dimensional stability as well as heat resistance. Other materials may work okay, but results may vary.