Well, I promised I'd show how this works.
The full instructions with detailed photos can be found here.
Do check it out.
Here are some snippets..
That's the Hella projector shield. (screwhole already drilled)
That is the new brass shield.
Plus alternate orientation (shown above) for a modified splash. I like this one best and will probably use.
Before and after. (Note this is with a 55 watt halogen bulb. The HID kit will be here next week)
The modified orientation..
Took me only 20 minutes to make both shields.. and a couple hours to test
and document everything. Also did a test where I painted the new shield black
to eliminate stray reflections, and found absolutely zero difference in the light
pattern between that and the unpainted one. To be absolutely sure I
took photos of each pattern at F4.4 1/15th 1/30th and 1/60th with
all different configurations so I could look for any stray light, and found nothing.
The area above the cutoff was virtually identical in all of them.
The final shields are thus unpainted.
I'll try to stick the HIDs into the same housing and add some photos of it
when they get here next week.
The brass sheet cost about $2, and 4 screws were $0.07/each,
Need tin snips, a drill and a screwdriver. My hella projector
housing is held together with 3 philips screws. The shield and lens
assemble is held to the rear reflector with 4 philips screws.
[Modified by Daemon42, 2:35 AM 10-15-2002]