Hi Guys,
I know this was done a couple years ago by Kissajew86 & WTVa, thank you to WTVa for all of his advice in doing this project. Thanks to Wavex for his advice and a good deal on the spare headlight. I decided when I did this that I wanted to also write up a DIY guide with some pics of it along the way to share. Here ya go!
What you'll need:
pair of projectors from '03-'05 R6
spare FZ6 headlight (optional, but recommended)
1/8" x 3/4" steel plate (mine came in a 3ft long section)
hack saw
dremel with metal cutting wheels (you'll need several)
flat black high temp spray paint
bench vice
threadlocker
quick-set epoxy
Step 1: Pull stock FZ6 headlight apart. I did this using my oven to melt the black silicon holding it together. Pre-Heat the oven to 350F. Turn the oven OFF. Place the headlight on a cool pan into the oven for 10 minutes. Remove prompty and pry the clear lense of the headlight off, careful not to break any of the retaining tabs. Then use the aiming/adjusting screws to remove the reflective housing.
Step 2: Prepping the R6 Projectors. You'll need to cut off the two tabs where the R6 used to mount to the adjusting screws of their original housing. Also remove the white-plastic thing with the screw in the middle. This screw is one of the places that you will be mounting your new brackets.
HID conversion
I also chose to make the right set of projectors into low beams by creating cutoffs. If you remove the front of the projectors, you can remove the lense and see the cutoff behind them on the left headlight, but they are not present on the right headlight. Using several folds of aluminum foil, I was able to make the exact same shape as the cutoffs of the left headlight, paint it black, then place it in the right headlight projector. The catch is that the inner projector of the right headlight is not convex like the other three, it is a flat lense. You cannot creat a cutoff for this, so it will remain a highbeam light pattern, whereas the other three will run as lowbeam light pattern. In step 5, you can kind of see that this one lense is a different shape than the other three.
Step 3: Time to set up some mock brackets in the FZ6 housing that fit the R6 properly. I made mine out of cardboard. This will make fabricating the metal versions much easier later on. The two points where you will mount the two brackets are here indicated by red arrows. There are screws going into the projector housing at those locations that you will remove and put through a hole in the brackets with threadlock later.