the front glass thing i don't have a good picture of but i took some acrylic sheets from a plastic supplier for $10 from their scrap pile as i didn't need it to be a big piece. then i went to my old school where i'm still buddies with the teacher (i buy him a 6pack and i get the woodshop + metal shop for a school year
) and cut pieces big enough to cover the headlight, but small enough to heat in my kitchen oven. next i took the old glass and made a mold using drywall stucco and added my own shape to it to accommodate the protruding projector. shove all of that into the oven, let the glass melt into the mold and next was back to the metal shop to use the band saw to cut the pieces to size and the rest is easy, some caulking to put it all together. total time spent was probably 3 hours and $15 in supplies.
as for light performance. it's ridiculously great.
- in that picture, i'm about 8 meters from the wall and the width spans approximately 5-6 lanes AT 8 meters. in other words, the spread is serious.
- as for throw, honestly, i only use high beam if i want to see what's above the cutoff, otherwise, the throw and brightness is at least over 300m away. i'm not sure why the gif shows a ghosty cutoff line but in person it's just one big beam, no line in the middle. it's a benefit for me as i drive daily home late on the trans canada hwy where some parts have no overhead lights. by the way, that picture was taken with the generic then 3 year old (currently 4 year old) ebay crapper ballast. when i'm done with my retrofit, it'll be sporting morimoto ballasts and oem philips D2S bulbs.