hi, you guys are probably reading this and wondering why. Well I want to do it. I just haven't found out how I going to do this but I'm definately going to do this. I purchased a set of those 7x6 H4 conversion headlights and that is what I want to use. I want to open the sealed beam and stuff the projector in there some how. If you guys heard or seen anyone doing this mod, please let me know. I'm trying to do this mod on a 1996 toyota tacoma. Maybe some here already tried this, I haven't came across the thread. Thanks for you help.

Yes, someone has tried it. I think he used an aftermarked el cheapo 7x6" sealbeam that already had projector in it, as a basis. Obviesly the projector unit is way below world class, so he swapped it for a pre 2002 Audi A6 projector or similar. In general, it is always easier to swap projector than to invent mounts in an existing reflector headlamp.

I put some Hella 90mms into some APC 5.75" round units. Just slow trimming of the round piece to get the projectors guts to slide in. When I figured where I wanted it, then I trimmed the plastic piece of the Hella to accept the curved back of the unit. Seal them together and the unit sill uses the vents on the Hella (which you wouldnt have). Throw a trimmed, stainless dog bowl around the lens to hide the projector's guts and to catch the stray light and seal the round units lens back on.

It was fairly straightforward, however you would need to find a way to seal the entire projector into the unit (ABS?). At least it might give you some ideas.

-Jon