Managed to crack on with the projector retrofit today and fabricate some supports....although I also picked up a hot bolt and melted the thread lines into my finger and thumb!
Crap! I am awfully sorry to hear that. Get the ice packs ready!
I still cannot wait to see the outcome of your retrofit. I realized that what was most wrong with mine, besides the failed alignment and positioning of the left lens, is the shroud which is just too big for the reflector and makes everything look hideous and over-sized.
My retrofitted head lights are in my other house which is rented at the moment but I am thinking of taking them as soon as the renters leave and re-opening them and fixing everything. I may not actually use it because my aftermarket head light units are great but at least they will be ready as a spare/replacement in case anything happens to the ones I currently have. I'll hopefully order new shrouds, fix the positioning of the projector lenses, and remove the two rings on the main beam's reflectors and leave only the ones on the lenses.
I'll have to do all of that before February, though, which is when the Spring semester in my university starts.
Would you mind linking me to where you bought the projectors and shrouds? Thanks!