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HID Projector Lamps
Well, like I originally threatened I have finished mounting E46 (audi/bmw) projectors with HID bulbs/ballasts. The projector shrouds aren't complete yet, but the projectors are at least installed. It's simply a modification to the reflector housing so it can still utilize the headlight casings own leveling bolts.
The nice thing about this setup is I won't have to worry about casting off glare from the reflectors of a traditional H4 HID setup (not that its terribly bad in the first place, and can be remedied with a proper glare shield), and I get that pretty vibrant semi-purple flicker when you view the fresnel lens at just the right angle.
I did fabricate a custom cut-off shield on the projectors themselves to accentuate the effect.
Here's my step by step, though I doubt anyone would be interested in doing the same.
The projector:
http://www.vehicross.info/gallery/da...eadlights1.jpg
Opening up the headlight assembly (via boiling water)
http://www.vehicross.info/gallery/da...eadlights2.jpg
More of the assembly open:
http://www.vehicross.info/gallery/da...eadlights3.jpg
Cutting the opening for the projector:
http://www.vehicross.info/gallery/da...eadlights4.jpg
Test fit of the projector in the reflector:
http://www.vehicross.info/gallery/da...eadlights5.jpg
I cut out and reshape several plastic mounts from an electrical housing for the projector to mount to on top the reflector housing.
http://www.vehicross.info/gallery/da...eadlights6.jpg
Using high-strength plastic epoxy and sanding the areas to be applied, I glued the plastic mounts to the reflector.
http://www.vehicross.info/gallery/da...eadlights7.jpg
The projector mounted/screwed to the plastic shafts.
http://www.vehicross.info/gallery/da...eadlights8.jpg
Another view of the projector mounted to the reflector housing.
http://www.vehicross.info/gallery/da...eadlights9.jpg
All powered up to the ballast, testing heat/operation.
http://www.vehicross.info/gallery/da...adlights10.jpg
projector light hitting the wall. the camera is a little overwhelmed so you can't really see the distinct cutoff. Notice there is no light hitting above the cut off.
http://www.vehicross.info/gallery/da...adlights11.jpg
Reflector remounted back into headlight assembly. Ready for shroud around projector, then to be resealed with clear cover.
http://www.vehicross.info/gallery/da...adlights12.jpg