2. Mounting the projectors into the headlamp assembly.
(This includes designing and fabrication of a base that holds the projectors in place inside the stock HL assy. )
These are the key points to be kept in mind during this phase :
1) The base should be easy to remove if you want to in the future. It shouldn't leave any permanent damage behind when removed.
2) The base should comfportably fit in the Headlamp assembly and yet leave enough room for the projectors without touching the inner-walls of the assembly or lens anywhere. The base should old the projector units firmly and never get loose( you wouldn't want to keep opening and servicing the headlamp again and again once it's finished)
3)It's better to have a base that's angularly adjustable to be able to adjust the headlamp beam like in stock reflector based setup. For this reason, I think it's best to mount the base onto the rear wall of the assembly, onto the bolts which hold the stock reflector.
I made my base at a welder's place with iron sheets. I also welded threaded metal "nuts" to the base, so that the OEM headlamp assembly's reflector adjustment bolts will fit into them. Also, I drilled holes where necessry to hold the projectors firmly using bolts. Had to sit an entire day at a local fabricator's place to get this thing made, from morning to night!
I then painted the iron, so that it wont rust. This is how my bases looked like:
Sorry I don't have more pics to show the welded nuts, close ups at different angles.
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