I'm retrofitting Hella 90mm into my stock housing.
Which bondo can I use inside of the housing. Something that is easy to work on and won't crack in high temp. and something I can get it from GTA area.

Thanks.

I mounted my 90mms with this:



There is info about it on the tools and materials page: http://faq.auto.light.tripod.com/tools-materials.htm

If you dont wear gloves while using it, wash your hands soon with warm, soapy water. You will be able to remove what gets on you. Make sure you mix it in small batches, it dries pretty quick.

I have had my lows mounted with this since Feb, it has held up very well against the temperature differences and the limited exposure to the sun that it has gotten. It is also sandable and paintable.

-Jon

Yeah and that stuff is cheaper than JB Weld brand. You can use thinners like water and alcohol to smoothing the mixed portions of bondo. It acts like a lubricant and keeps it from clumping. Just a little trick I learned.

I always used the JB Weld because it certifies on the back of wrapper that it is good to like 600 deg F. And I like those numbers. I have no idea what the above listed stuff is good to, but I sure like the piece of mind in knowing that I never have to worry about temps with my HID on as DRL in the hot summer temps. Mine has not shown any signs of heat damage and is not brittling

Thanks.

Is there a something I can use it to shape around the projector, so it would look like somewhat stock?

I used aluminum foil for the 'bone' to give it form til dry. See here: http://josch.wilksfamily.com/LEDandMarker/LEDretrofit.htm
The foil trick is kinda shown there at that link.