D-Bob great write up. I have also been a member to HIDPlanet for years actually before when it was called HIDForum.
Anywho... Since there is a problem with the aftermarket housing sticking out of the grill, could you not use the stock housing as long as the fluted lense was sanded down to make it clear? That aluminum angle looks like it took a lot of work and tools I don't have
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I know members on HIDPlanet that have used the fluted lenses with their projector upgrades (some actually did not like the look of the projectors but wanted the performance), even though the cutoff is not sharp and crisp as it should be (FYI the fluting blurs the cutoff - for the people who wanted to know).
So what do you think?