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When you "retrofit" your lights to HID's, is this basically just taking the Projector Housing from a vehicle that has HID (like Audi, BMW, etc) and putting it in our stock location? Then adding the HID kit with the harness, ballast and Phillips bulb?
You remove the projector unit from the original factory headlight, then you find a way to mount it into your reflector housing so you can retain the factory leveling adjustments. The most important part when you mount the projectors is making sure your cutoffs are level in terms of rotation, since you will be able to adjust them up/down the the factory adjusters.
If you already had a reflector HID setup you can usually leave the ballasts where they are, but if you had a halogen setup you'll have to mount the ballasts also. Check out hidplanet.com/forums for more info, their site has been on the fritz recently though.
But if we have halogen setup, we'd have to cut and make room for the projector to fit in and be tight?
yeah, usually you will cut a hole in the original reflector where your halogen bulb used to sit so that the projector can sit inside the old reflector. This locates the new HID bulb in about the same place as your original bulb. You'll have to make sure it doesn't hit the back of the housing, as well as the front (clearance issues). You will want to mount the projector as far forward as possible to get the best output, but you also don't want to hit the front lense with the projectors lense.
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