Hey Fellas,

So the ballast connector (silver metal piece) when attached to the projector is too long or deep towards the back of the headlight and there is no way to move it forward some (I need about 1/2 inch).

It runs into the piece of metal (framing I assume) behind the headlight. So the solution that is apparent is to cut a hole in this that is large enough in diameter for the ballast connector to fit into.

I thought a sawzall might do the job but I don't have one so it's off to Home Depot to see if I can rent one because I really don't want to buy one.

So my question is do you think it's possible to cut through that? Can't lie, I'm kinda scared.

I'd re-prime and paint it to prevent rust. I've just never cut through metal like that, any tips?

Duke

 

you can use a drill bit to drill a hole in it. i think its called a hole saw. but its basically a huge diameter drill bit that will do the job just fine.

 

Should be ok. Just make sure there's nothing behind it that you could damage. You could probably just use a drill to make a small hole instead of a sawzall. Just use a bit for cutting metal.

 

Cool, actually just off the phone with my girlfriends dad and he has something similiar to a sawzall, I'll just need to get a metal cutting bit for it. Well I'm off to NAPA to get some primer and paint to cover the bare metal to keep it from rusting after I do the cutting. Then I need to put this bad boy back together because I have dinner plans tonight.

Round 2 tomorrow. Hopefully I win.

Duke

 

Yeah I'd just have to do it quite a bit because I'll need a hole that's about 2 inches in diameter.

Duke

 

the bit look like this
http://www.lowes.com/lowes/lkn?actio...e=038548101040

 

Your going to want a hole saw kit like used to drill holes for plumbing,dryer vents,etc...Those you can rent from Home Depot.They can be used in metal and would make a perfect hole in the diameter you choose because they have a small drill bit in the center to keep you straight.I wouldn't use a sawzall because the blades are too long and you would endanger whatever is behind the area your cutting.Trust me,Use the hole saw!



Bob

 

Here is the holesaw kit you should use and it is ony $20.
http://www.homedepot.com/prel80/HDUS...ce=MOSTPOPULAR
Click on Holesaws and accessories.

This is what your looking for=
BLU-MOL
No. 6561 7-Piece Hole Saw Set, Homeowner, Aggressor

Model 4516561


Bob

 

Thanks fellas.

Round two starts in 10 minutes.

I bought the bit for the drill that allows you to drill a hole in metal (it's 2 inches), and $15! The other ones that were cheaper were only for wood and pvc.

I'll be spraying the area being drilled with wd-40 as a lubricant since the metal is pretty thick.

I'll also be covering the bumper and fenders with blankets so any hot metal shavings do not burn into the paint.

Thanks again for the help, hopefully it goes well and I can finish today.

Duke

 

Can't wait!!The suspense is killing us!!! Make sure to get good photos please.If this looks good I pland to follow in your footsteps and I am also putting HID in the foglamps.Jeeez I hope that's legal.I'll be burning out peoples retna's!!


Bob

 

Just an FYI, the bit that 04procomplariat posted a picture of is called a "VariBit".

But a holesaw, particularly carbon tipped would suffice. I wouldn't use a sawzall.

 

Ok fellas, it's finally done. There is a few final touches to do (velcro mount for ballast and sleeves for some of the wiring) but it's installed.

I'm totally beat. I'll upload some pictures to the gallery and link them to the other thread while I'm at work. I'll also provide some information.

Duke