9/2/2018 : Headlight Blackout and Xenon Retrofit
The idea here was to black out the headlights and install a set of ACME H1 projectors with E46 shrouds, that ideally mounted in the stock bulb hole with a little Dremeling.
The problem I found was that the bulb hole is not centered in the low beam area, so the projector shroud wouldn't be centered. After racking my brain, I decided to engineer a bracket to hold the projector exactly where I wanted, independent of the hole. I had a 3D printer that can print ABS, so I modeled it in CAD and printed it out. It was perfect, or so I thought.
After about a day of use, the projectors were drooping. Turns out they get pretty hot, and had melted the ABS enough that it was sagging. Luckily I have an X-Carve also, so I machined aluminum brackets to take their place.
I used bolts and rivets to attach an L-bracket to the top, and metal wire to attach the bottom of the bracket to the bowl. This ended up working really well, and are going strong to this day. The cheap halos I bought however, wouldn't last more than a few weeks.
