[rsw81]

Step 4: Now that you have a basic idea of what shape you'd like your brackets to be, it's time to make them out of metal. Keep in mind that these not only need to fit in the back of the headlight housing, but that they also need to clear the inside of the front/clear part of the housing which is a little smaller. It helps if you try to keep the projectors as far from the midline as you fit them. You also want to make sure that you are keeping the projectors straight up as you mount them. An easy way to tell is to look at the two screws on the back of the projectors where the bulb-retaining clip is located. Those two screws should line up straight up and down. Here are some pics of the brackets that I made after I painted them flat-black.

Making the brackets is a long, tedious process. Be patient. I used the hacksaw to make the general cuts as a dremel would take too long. After using the hacksaw, I used my bench vice to make the bends needed, using a piece of 2x4 as leverage to lean on the metal. I gave each bracket approximately 1 inch forward lift to meet the projectors from the adjusting bolts. I then used the dremel with cutting wheels to slowly grind away section of the bracket needed to get the proper fit and angle of the projectors. This involves repeated putting the brackets on the projectors and test fitting in the headlight housing, and then removing them to trim the brackets and try again until you get it right. Tedious, time consuming, and sometimes downright infuriating... but worth the effort. Not only is the shape important, but the whole that you drill into the bracket is equally important as this will determine the angle of the projector and it's relative position inside the headlight housing. Once you think you have it right, test fit the front half of the headlight housing to make sure it will clear the brackets that you've made. I had the most trouble getting it to clear the bottom bracket. Mounting the projector as high as possible relative to the top bracket would help avoid this situation for those that do it in the future.

Once you get it right, I epoxied the plastic adjusting screw nuts into place onto the brackets as they were not that snug on the brackets that I made. This will prevent them from shifting around later, causing the fit that you worked so hard on getting right to now be wrong.

Now that you have the brackets the proper shape and the plastic nuts epoxied (and dried), remove the brackets and spray them flat black. I chose to cover the plastic bits with tape so that paint would not get into the threading.