I wanted something factory looking (and affordable!) but still retain my adaptive bi-xenon headlights.
Here are some pics and notes on my "Devil Eyes" headlight mod that should work for all B7 models.

First I had to construct a mounting rail for the LEDs:











Attached the LEDs:





Test fitting ....



Next I painted around the leds with some flat black.

Then I fabricated some end caps to cover the ends of the LEDs for a factory clean look.

Here are the LEDs all cleaned up, painted and ready to go:

 

a little dremel action and the headlight is reassembled!





Next I painted the underside, sides and top of the headlight flat black to clean everything up.





Time to reinstall ...







Lights lit in "Stand By" Mode (low voltage) ....





The pics suffer from a bit of brightness over-exposure - THAT'S GOOD!

Right away I saw a HUGE improvement in brightness and intensity compared to my first try (passenger side):









The modded headlight (driver side) is absolutely AWESOME!!

The LED installation is extremely clean and definitely bright enough for daytime use.

I'm gonna go rework the passenger headlight LEDs now. I'll post final pics later this week!

 

Big difference - much better. Working on the other headlight now!

 

You did an amazing job on the lights. How long did it take you? Although the pictures made the job seem easy, I have a feeling it was a lot of work?

Thanks for sharing the pictures - your car is seriously evolving into one of my favorite S4's out there!

I will post some of my new pics soon....I had some more work done too.

Did you mod the chip yet? That is my last stage and I am confused who to go with or who to do the work....I know this is beyond my capabilities and if you have any references, please let me know.

Awesome job man.......I have looked at the lights 10 times already and I would love to make the same changes on my car.

 

"How long did it take you?"

It takes about 5-6 hours per headlight to assemble, wire and paint.

"Although the pictures made the job seem easy, I have a feeling it was a lot of work?"

It wasn't hard work. It just takes a little time, patience, and BEER.

"Thanks for sharing the pictures - your car is seriously evolving into one of my favorite S4's out there!"

Thank you!

"Did you mod the chip yet? That is my last stage and I am confused who to go with or who to do the work....I know this is beyond my capabilities and if you have any references, please let me know."

No not chipped. Drivetrain is totally stock for now. I don't think I'm going to waste my time on a chip. I plan on paying off the car then when I do I'll pull the trigger on a supercharger (ECU will need to be remapped). I want to go out and scare the hell out of an RS4....maybe even beat one.

"Awesome job man.......I have looked at the lights 10 times already and I would love to make the same changes on my car."

Yeah the more and more I look at the completed headlight the more I can't wait to drive it! I took a bunch more pics on how I constructed the LED rails for everyone too. The second headlight has been going really quick.... around 3 hours into it. I have about an hour or two worth of work left.

 

What did I need?

-Rotozip with Grinder Bits
-5 or 6 dealer license plate rings (yeah those things we always threw away!)
-Hot Glue Gun and glue sticks
-Black high-temp silicone
-Flat Black Spray Paint (Krylon or Rustoleum)
-Sandpaper
-Red and Black Wire (to power leds)
-Clamp and Snap Wiring Connectors
-Radio Shack Hot Knife
-Torx bit sockets
-Craftsman Mini Torx driver set
-Tin Snips
-Heat Gun
-Mechanic gloves (wore when pulling apart headlight - hot!)
-Beer (not required but helpful!)
-Two packages of Alpena LED strips from Advance Auto Parts (4 strips total)
-Big enough ***** to hack up $1000 headlights

Do at your own risk. I'm not responsible for you destroying your headlights!



This is an example of a license plate trim ring section I used:



Although hot glue is shown, only use a very little bit of hot glue to tack the pieces in place.
Once all pieces are tacked in ... I used high-temp silicone to attach permanently.



Using smaller sections of plastic (as shown above) I started at the big end and trim a little as needed to attach in place.



Here is an illustration of how the plastic pieces "hook" into place:



Instead of hot glue (shown) I ended up using black silicone and ran a bead all the way down the groove.



This picture shows a piece of plastic that was used at the very end of the small side.
The edge that hooks into the "groove" I had to shave a little bit to fit properly:



Once all the plastic pieces were tacked in place, I filled the backside with silicone (NOT hot glue like shown - pic coming soon).



I just continue to build the rail ... cutting, trimming and tacking in place.















The LEDs already have double-sided tape so they were very easy to attach.
I just used two strips per headlight, trimmed to fit the length. The power wires are led out on each end.



The "end-caps" are just more of the same plastic pieces just cut, trimmed and glued in place.

 

All done - LOOKS SICK.

 

Sweet mod

looks AWESOME

 

Thanks!

 

Here are some pics of the LED DRLs on during the daytime ....