I have to dig for pictures of that. I basically made a little metal bracket that lined up with the projector and screwed it in the back of the housing (easiest thing I could think of that was within my abilities)

 

Best beside TL is probably RX350BX with either polished/STi-R lens, it's smaller than the FXR and nothing beats OEM quality, but that's personal preference

Cutoff of my RX350BX with polished OEM lens.
http://i133.photobucket.com/albums/q...psb04db5f6.jpg

Either way, good work on the retro Did you seal up other open spaces around the E46R shroud?

 

Thanks. That cutoff looks amazing, I'll have to take pics of my cutoff once put everything back together (the paint is still drying on the bezels, plus i want to do another coat before they go back in). Right now its still open from the back, but I was thinking about trying to find those thin aluminum sheets from home depot, cut to the shape of the back housing with a hole for the back end of the bulb and use a rubber grommet to seal that up. If I went that route I'd paint the cover black as well. But I need to source material to even attempt trying that.

 

I think vacuum forming will look better than a sheet metal.

 

I'll have to see if I can get access to something like that.

 

Yeah I don't know much about vacuum forming, but I have seen some DIY on other forums so it's definitely do-able.

 

does the bracket cause the projector to be fixed in place? or are there still adjustment screws?

 

Would only one of the bi-halogen units be sufficient? Or perhaps one of the bi-halogen units for low beams and paired with an additional high beam of the less expensive option?

 

^ Most certainly yes. If it wasn't for the design and having two lights on each side, you could use just one bi-halogen unit on each side as it would work great for both low and high beams. And, yes, you could use one of the bi-hologen units for the lows paired with an inexpensive high beam option. The bi-halogen unit will be the workhorse with the other high unit contributing mostly for looks.

If you want to go with one single unit like dabigesii did, then consider using this 90mm unit:

Susquehanna MotorSports - Auto Performance Product

In general the larger the diameter of the light, the better the output, if all things are equal regarding quality. So, the 90mm unit would work great as a single source unit and it's reasonably priced at around $150 per light.

Regarding mounting it and then adjusting, Hella makes brackets that you could modify into the housing:

Susquehanna MotorSports - Auto Performance Product

The advantage of using this is it is OEM adjustable with a three-point system.

 

It allows adjustments but in a slightly crude way (I can loosen the screws and adjust the position on the sliding fitment then screw back in), I just used materials I had available at the time. I'm actually cleaning things up now that I know it works. Painting all the brackets black, while I'm waiting for the fiberglass to cure so I can sand and paint everything black.
bezel painted black and test fit back on the projector

 

That looks pretty good, I haven't pick out a shroud for my RX350BX retro yet, I might consider the E46R.

 

pics of the brackets off the housing before paint

 

finally have pics, like I said...it's crude, but it works and I can adjust my light up and down.



Just have to check the beam pattern again and then I can reglue the lense back on the housing.

 

^ Look at the brackets I posted up that Rally Lights sells. You need a three-way adjustment mechanism to properly align the headlights. Yours is pretty ingenious but won't fully work. I'd bet you could take one of the Hella brackets and use with your lights.

 

I'll check those out, thanks. Here is a quick pic while I was aligning my lights.

I lowered them slightly after this pic, but I just wanted to see the cutoff.

 

i just placed an order for

(2) hella 90mm classic projector low beams (h9 bulb)
(2) hella 90mm classic high beams (h9 bulb)
(2) hella mounting brackets

my plans are to fiberglass some metal tabs into the bucket, and use those as a mounting point for the brackets/light housings, i'll repaint the buckets matte black

the only thing i'll need to figure out is the angle/adjustment, and what shrouds to use to make this look all pretty

anybody have some tips on how to get this soft rubber glue off of the bucket + headlight covers? it's pretty annoying to peel by hand and i'm afraid to use anything to scrape it off since i don't want to damage the covers

 

I used a razor blade and was very careful with it.

 

I finally tried to see how I would mount the hella 90mm classic lights in the housings, there is no way these are fitting unless they're directly behind the housing, almost completely outside

 

Which ones do you have? Any pics please?

 

after playing with it for a while, i did get them to fit inside 90%, the little brackets are preventing it to go in as far as i want, so i will be shaving parts of the headlight bucket away to make it mount straight instead of clocked

 

i looked at the rotary extreme kit, which includes the hella 90mm lights, and the only way they installed these required a section of the headlight frame to be cut away, i don't have a problem doing this

does anybody have a rotary extreme sleek headlight kit, that they can pull the metal mounting frame off, and trace it onto a piece of cardboard, and mail it to me, i will pay you for your time, i need both driver and passenger side to be traced

or if you have a set for sale, i would buy those also!!!

these are the brackets i'm talking about

 

well thats interesting for sure. flippy lights are still my favorite

 

did finally get it to fit?