Projector Retro, It FINALLY stopped raining for 2 consecutive days! Options

[GriffGirl]

So I've been working towards this for a while, and I finally got the time and a dry weekend to complete my projector retrofit. This is my first time doing anything like this, so go easy on me! I used Rayme's lenses and his stickied How-To write-up for guidance. I took pix along the way sort of as an appendix to his write-up for those of us who do better with detailed visuals. I put clear lenses on all 4 headlights, but the pix below specifically pertain to the low beams, as the high beams is self explanatory.

Before:


Lense Removed from one of the low beams:


"Exploded view" of the components that make up the low beam internals:


Tiny stainless bowl of vegetable dip mix (!) and bathtub faucet ring for shroud and bezel use:


Cut out the bottom of the bowl for the lens to fit through:


Cut out the reflector to fit the back of the projector through - no turning back at this point!


Test fitting the projector. When I marked up the reflector to mount the projector, I removed the lens from the projector so I could make sure the cutoff shield was level. Then I test fit the projector in the reflector only, to make sure it bolted in correctly. Once I was sure that it was correct, I mounted the reflector back into the headlight bucket, tightened it in, and then drilled the projector mounting holes all the way through. By doing this, I'm able to adjust the alignment of the projector itself within the reflector.


Test-fitting the shroud I made. I had to cut a notch at the top of it to allow it to recess into the reflector without the glare shield mounting point obstructing it.


I also bent the bottom part of the shroud up to flatten it down some. The bent part doesn't show once it's in, but it allows the shroud to fit better into the reflector unit. I probably could have just cut this part out, but I wasn't sure how much of that would show, and I wanted to keep it as finished looking as possible.


Test fitting it over the mounted projector (still without the lens on it, so I didn't risk chipping or scratching the glass lens:


Mounting the shroud to the reflector unit. JDM, yo!


After.
This morning I learned that JB weld was a bad idea, as it doesn't bond metal to plastic well at all. Note the top part of the shroud on the passenger side. Now my celi has a lazy eye. Bummer. If I get home in time tonight, I will take it apart and figure out a plan B. It will probably involve using the mounting point where the glare shield went to screw the shroud to. The screw is small, and will probably not show at all, but we'll see.


Close-up of the driver's side. Other than the issue with the passenger shroud, I'm really happy with how they came out. Once I get the passenger side fixed, I will aim them and take night shots of the cutoff. It looks really good though and has nice color banding at the top.

[GriffGirl]

It's supposed to be warm and sunny this weekend, so if I can gather support and minimize the resentment at home, I'll be delving into the wonderful world of fiberglass this weekend! I've looked it up on line and I think if I use some thin-ish felt to make the form, and then glass over that, it should work out pretty alright. Now I just need to decide what color to spray the shrouds. I think I'm actually going to stick with chrome. I like how it looks and it looks more OEM to me than spraying it an actual color. If my car were black, I'd do matte black, but since it's silver, I think the black would stick out too much and not flow as well, visually speaking.

All ideas and input are more than welcome!