I've been finishing up some wiring and while finishing up the install for my HIDs I ran into a snag so I figured I would post my solution in case somebody else runs into the same issue. The problem is that the space behind the light bulb housing is very limited. The HID bulb sticks out quite a bit more than a standard H4 bulb, so there was a problem getting the housing mounted. My solution was to widen the existing hole. If you have a dremel then this is a fairly simple task. Mine is unfortunately burned out. Here is how I did it.

Use some tape as a guide and to protect the surrounding area. Drill 2 small holes in the top corners. (Make a face)



Use a larger bit to expand the 2 small holes. These will give you nice round corners in the end and help with the cut later. (Scare it)


Use a center punch and make several marks down the sides. (Make it cry)


Use an angle grinder with a metal cutting disk and cut along the tape edge into the holes drilled earlier. (Give it a unibrow)


Use a small bit and drill along the punch marks made earlier. (Make it cry more)


Use some pliers to break the metal loose. (Rip its face off)


Once the scrap has been removed use a file to smooth out the edges. Then hit it with some paint to prevent rusting.


Now the housings can be mounted without any issues.



The final product.


Total time was about 20 minutes per side

 

Whats the beam pattern look like? clear cut off and no glare?

 

I haven't had a chance to check yet. Its hard to tell in a small garage full of stuff. lol. I'll try to pull the car out of the garage and use the garage door and try to get some pics. From what I have seen with these housings on other people projects they are pretty good. They are made by Bosch and are DOT legal.

 

I found something like this for jeeps, they use the same housings as us. Mind me asking how much this set you back?

I got a busted headlight tab, and the housings/bulbs I am looking at will set me back about 160, but they are 80w/110w beams.

 

The housings were $50 on eBay for the set with no bulbs. Just search for Bosch H4. I don't remember how much I paid for the HID kit. It was one of those make an offer things on eBay. I think I offered $65 or $75.

 

Here are the pics of the beam pattern. It was still fairly light out so they aren't the best but they should work.

Low beams


High beams


BTW. These are a huge improvement over the original sealed beam lights.