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:
![]()
Opening up the headlight assembly (via boiling water)
![]()
More of the assembly open:
![]()
Cutting the opening for the projector:
![]()
Test fit of the projector in the reflector:
![]()
I cut out and reshape several plastic mounts from an electrical housing for the projector to mount to on top the reflector housing.
![]()
Using high-strength plastic epoxy and sanding the areas to be applied, I glued the plastic mounts to the reflector.
![]()
The projector mounted/screwed to the plastic shafts.
![]()
Another view of the projector mounted to the reflector housing.
![]()
All powered up to the ballast, testing heat/operation.
![]()
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.
![]()
Reflector remounted back into headlight assembly. Ready for shroud around projector, then to be resealed with clear cover.
![]()