I think Northwest fab might have a plasma table. I have no idea if they would do outside work or not if you give them the dxf file. I used to give dxf files to a buddy and he would cut them out, but they sold the table to NWF I believe. Sure beats doing it by hand! Also sinking the projector does look like the best option.

 

I think I'm going to cut them out of a piece of 1/2" UHMW or nylon, it's easy to work with, won't corrode, and I'll be able to seal it really easy.

Tonight's cutting. It'll be tidied up after everything fits:




I bought a few cutting wheels for my Dremel to make my life a bit easier. Anyone thinking of this has gotta get the plastic cutting wheels!!!

 

The guys at NorthwestFab are great! Very willing to help out with custom parts. I've bought a lot of 4x4 parts from them over the years too.

 

Little more progress today. Bought myself a scroll saw so I could cut out my little adapter pieces. I printed out my CAD file 1:1 and used spray tack to hold it to the nylon:




As you can see, I started out a little shaky...But it got better as I went along. The material is 1/2" reinforced nylon. An absolutely awesome material to work with and very strong.
I had to improvise the pieces a little, but they work fantastic:

 

I will revise the CAD file to match my final piece if anyone wants it in the future.

 

Awesome job, I am glad I will have a bit more depth to work with on the first gen lights when I do this. Second gen lights have crap for depth for mounting.

 

GAH!! Looks so good so far!!! Keep on truckin!

 

Knowing what I do now, I would seriously consider the Mini H1 6.0 if I were to retrofit another set of Blazer/S10 lights. It would take half the time as the Mini D2S 3.0 have, but with a substantial reduction in output.

Then again, all the tough stuff is figured out now.

 

I planned on doing pretty much the same.

The stock reflector housing in the Denali lights are pretty damn big. I just got done building a fixture to hold the buckets so I can aim them with the stock bulb and mark out the pattern on my garage door. I'll then modify the reflector to accept the projector and put it back into the fixture for aiming prior to using some window weld to permanently attach the projector to the reflector housing. It's kind of a combination of epoxy retention & the JnC method on HIDPlanet. It might be overkill, but I don't want them moving around at all!

BTW, keep up the great work Ian! Those projectors look awesome in the s-series housings!

 

So I was trimming the shrouds last night... I was using the radial arm saw to cut the straight lines on the shrouds and had a bit of an issue. It was working really well, and I've cut a lot of plastic with no issue on this particular saw. Problem is, that shop isn't heated, and it was about -10C(15F) and with the wind of the blade, plastic gets reeeealy brittle....So anyway, I cracked one of the shrouds(chunked actually). Long story short, I need another shroud...It's ordered, but I have to wait.

Lesson of the day: Don't trim shrouds in the cold.