Rob i never liked the idea of using the reflector housing as it wouldnt be reliable. Looking good tho. Have you thought about a black shroud?
Jay, I agree with you, I'm concerned that the weight of the projector on the 2 plastic clips of the reflector would ultimately make it break from the usual road movement etc. I have produced a cardboard template which should be just fine for transferring to steel and that should work a treat!
You have probably see the thread Jon TDi did about his retrofit and he used a piece of carbon sheet to hide parts of the projector from the side. I'm not keen on the carbon finish however the DVD case is a perfect match and can be bent to shape using the heat gun...tried it tonight and it works just fine.
As for the black shrouds, that was on my list of ideas however because the main beam is silver I think the shroud should remain silver as it will just seem better visually. If it doesn't I can pull it apart and give it a spray!
I'll try and get the templates cut tomorrow and carry out a temporary fitting to see how it works. The are also a couple of other things to do too but that will have to wait until its finished for you lot to see!