Thanks! I bought some 3" PVC and end caps today to seal off the back of the light and did the other projector today start to finish. Hopefully I'll have enough free time between classes and work this week to scrape the sealant off the housings and maybe next weekend I can get the backs made!
I remembered to take pictures of most of the steps as I did the second projector today:
With the lights disassembled, tape off the lens and bend the tabs in to pull the bulb cover out:
Using a 3/4" socket, tape to add thickness, 1/4" drive extension, and a 1/4" drive to screwdriver bit adapter, make a centering guide for the template:
Line up template:
Trace template and make a rough first cut with a Dremel and a cutoff wheel:
I've had my Dremel for years and this is the first time I've tried using the flexible shaft attachment. Not having having to hold the entire tool in your hand makes working with it so much easier!
Using a 60 grit sanding bit, sand out the hole for the projector and test fit:
Sand down this tab like so if you plan on doing dual signals:
Drill holes for mounting the projector, cut bolts to the proper length (I wasn't sure what I needed when I was at the store. It's always easier to buy longer and cut than to go back and buy longer bolts), and trim the shroud to fit around the projector (I loosely bolted the projector to the reflector before removing the tape to fit the shroud. The trimmed edges are sharp enough to damage the chrome, so make sure you trim and test fit before removing the tape):
With the projector loosely bolted in place, connect the bulb and ballast to a 12 volt source to aim the projector and make sure the cutoff is horizontal. I used the battery for our backup sump pump because it was convenient (it's just a car battery). With the projector aligned, use hot glue to temporarily hold the projector in place. I didn't take any pictures of the aiming because I didn't have enough available hands to take pictures:
Once the glue sets, carefully tighten the bolts. Make sure you do not over tighten them and crack the plastic. I didn't take a picture, but I used two nuts on each bolt and hot glued around them to ensure they did not loosen:
If you are doing dual turn signals, now is a good time to attach the lenses. Screw the top lens and reflector in place first, then bolt the second lens and second reflector together. Again, I used two nuts with hot glue. The left and right side of the bottom turn signal reflector will need to be trimmed. You can see in the pictures below exactly what was trimmed. Using the pattern in the top signal lens as a guide, line up the bottom lens and liberally apply hot glue around each tab to hold it in place. (can you tell I like using hot glue?) The closeup pictures are of the already completed projector:
Use hot glue to hold the shroud in place and you're done!
Both sides finished:
I hope this combined with the links posted above are enough to guide someone through this process.
Modified by JettaGetUpandGo at 1:38 AM 3-22-2010