What do you think I need to do to get this (low beam)......



.......to fit in here:



the headlamp opening is in the middle/right hand side.^^^^^




Is there a certain distance from the glass that the projector needs to be? If it's too far back, will the reflector start to interfere with the beam pattern?

In "Alt 3" on
http://faq.auto.light.tripod.com/hid-upgrade-routes.htm

there is a discussion and links to consequences of having a projector unit too far in or too far out.

Thanks.....so am I going to have to take of the front cover of the headlamp to do this install...no matter what?

Bake those housings in the Oven!!!!(seriously)Heat the housings up in the oven with low heat for not too long and the front lense will come off way easier. That's how people do it on clubSi.com, I would post the link but their server seems to be down now, so go to www.clubsi.com and look in their "Tips and Tricks" section, there is a sticky thread there describing the whole procedure step by step with pics.

Well looks like I'm going to have to buy a second set of headlamps for this, because I have the worst luck working with heat, lol.

Is there a certain distance from the glass that the projector needs to be? If it's too far back, will the reflector start to interfere with the beam pattern?

Yes it will interfere with the pattern. I'm experimenting with a bixenon projector in a spare headlight (Toyota Tundra) and the present mounting location is pretty deep into the housing. There's all sorts of glare due to the output reflecting all over the housing's "floor". I painted the reflector black and the glare's gone. Luckily I have another spare headlight,I'm going to try mounting it closer to the stock lens.