ok this is my first time for writing a how to so be patent with me and post anything i need to clarify
this is a how to to mount the r6 projector headlights in a fz6.
Step 1: obtain a r6 projector setup. I found mine on ebay for $25. link: http://cgi.ebay.com/ebaymotors/ws/eB...RK%3AMEWA%3AIT
you will not require the external housing for the project since it is a diffrent shape anyways....
Step 2: once you obtain the headlight go to home depo. you will need the following supplies:
#1 you will need longer bolts than the ones holding the projector together. I used a nut to adjust the length, since there are various mounting depths requires. i will show pictures in another step. if you want to go through the trouble you can experament and find the exact lenght, however i did not. i bought 6 #8x3/4, 32 pitch machine bolts and 6 #8 32 pitch nuts.
#2 3/4"X1/8" steel bar, mine came in 48" lenghts
#3 black spray paint, i used high temp engine paint since the hedlight does get warm....flat black so it wont reflect....
step 3: now you should have all the supplies, when you are ready go ahread and remove the headlight assy, follow the manual on how to do this, remove the headlights from the assy, you should have something simmalar to this
step 4: warm your oven to 350 degrees then TURN IT OFF. place the headlight on a cool metal pan so it does not contact the oven, place in the oven for 10 min, remove and pry the lens off, the glue should be soft enough that it comes right off once you lift the tabs that hold it together. i used 3 screwdrivers to do this with. I took a while and had to put it back in to do the 2nd side. it should now look like this
step 5: there are 3 bolts holding the reflective unit in there. 2 10 mm and 1 8 mm with philips head in the middle. unscew them until the reflective unit is loose. you should be able to remove the reflective unit, which will look like this
step 6: you will need to use an angle grinder to cut off the tabs on the projector assy. test fit the projectos in the enclosure, as you can see where i have drawen red lines it is hitting the headlight housing. remove the plastic mounting swuares and start chopping, as close as you can get without actually disturbing the projector. do this to both units
Step 7 : you will need to create 2 brackets per side out of the steel bar. i have drawen the general shape of the brackets i created on the housing. you will need to use all 6 plastic squares as shown in the drawing. the lower bracket you will have to bend upwards since there is such a height diffrence from themounting screw to the mounting point on the projector assy
step 8: Test fit the brackets together and check for levelness. the projector has a sharp cutoff and must be mounted leval in order to work correctly. use the 2 screws in the back of the projector (the ones that hold the bulb in) and make sure they line straight up. also makesure the headlights look likethey are pointing straight, you will have some adjustment but not a lot. mark where your mounting holes in the brackets are and drill it out.
step 9: test mount the headlights with the new longer scews. mount the bolts on the screws and spin them all the way to the bolt head. then bolt the bracket to the projector and back the nut back so it pintches the bar to the projector. mount the projector in the housing and check for straighness. I even went as far as to mount everything back to gether and light it back up and check how everything was pointing. if something is off adjust your mounting holes accordingly.
step 10: once you are satisfied with your aiming, take the brackets off and paint the brackets black.
step 11. After the paint is dried mount everything back together, this time putting threadlocker on the nut so it wont come loose.
step 12. Place the front lens back on the housing assy, and reheat the housing assy in the oven to reset the glue.
step 13: put it all back together and your done!