Sciemmer, just a few questions on the retro. Did u have to split the headlights to do the projector swap? How did the bolt pattern line up with the FXR projectors to the lens? Did u use the bracket from fastheadlights or was it easy enough to do without the bracket? Thanks in advance!
I did not open the lights if that's what you mean by split them. I was able to get the FXR's in through the factory opening. I also used the fastheadlights bracket. You need it for the two bottom bolts of the FXR's. It takes a little wiggling but they'll go in there. I'll make some suggestions below for other folks that may be installing these.
FXR fitment:
Getting the projectors in requires some effort but isn't impossible. What truly is a pain in the ass is getting the bolts to slide through the fastheadlights bracket and through the FXR. I ended up opening the holes a little with a slightly oversized drill bit on the bracket and also on the projector to make the bolts slide in to place easier. If you have a strong enough magnet you can wiggle the projector a bit and the magnet will make the bolts come up in to place. Since I didn't open the headlight, I used the 3 bolt method and didn't use the top bracket. If you're brave you could drill a small hole in the headlight housing above where the other top bolt goes and be able to get the other top mounting screw in.
Installation:
I ended up getting power from the fuse box and running the power wire along the hood latch release cable to the radiator support where the relays were mounted. I ground the capacitor link under the body support bar above the driver side headlight.
Here is where I mounted the relays and driver side ballast. Ballasts are mounted with 3M outdoor mounting tape:
https://drive.google.com/file/d/0BzjivpH9PESXcGxtQWItbE8wMHM/view?usp=sharing
Ran the driver side connection over the radiator and mounted the ballast to the same spot as driver side. You can also see where I grounded the ballast, also grounded the driver side to the same bolt. (on driver side)
https://drive.google.com/file/d/0BzjivpH9PESXZ2hHTE15UlY3X2c/view?usp=sharing
Now, the best part of this whole install is extending the headlight cap. It is awesome and I enjoyed it very much.
Do yourself a favor and buy the extended caps unless you want to get crafty like my buddy did. We ended up cutting the entire back out of the cap, test fitting the thing over the D2S plug, realizing the side needed to come off as well and then building out the cap using 1/8 inch ABS plastic. Not pretty but it works for now. Glued everything together with CA glue and then sealed with liquid electrical tape:
https://drive.google.com/file/d/0BzjivpH9PESXajd3enp5ckdHYVU/view?usp=sharing
We could have cut the caps in half and extended them with roofing tape like fastheadlights recommends but we decided to get creative. If you attempt this method make sure to follow the original cap profile as clearance gets close on the side of the cap when you put the headlights back in.
Now for the results. I originally bought the fastheadlights kit back in February and sat on it until now because of the cap issue. I saw another person us AMP bulbs and igniters and originally tried that as it was easier to mod the cap for that. Well the output sucks because the bulbs do not go all the way into the FXR's and do not sit flush. If you buy the fastheadlights kit just use everything that comes with it. Here are some pics of the output, pics do not really do them justice though.
https://drive.google.com/file/d/0BzjivpH9PESXdU4teThKRDRRUFk/view?usp=sharing
https://drive.google.com/file/d/0BzjivpH9PESXWGJleS1VbmNqUUE/view?usp=sharing
If anyone has questions let me know.