I am starting a similar project. I've retrofitted a few cars before and cannot live with halogen any longer.
Rig in question is a 1999 Tahoe bought as a COVID project with a bad intake coolant leak. Ended up having "while you're in there" syndrome and did the heads/gaskets as well.
I've had a similar setup as the OP in my track car (E36 BMW) FXR projectors in updated housings. What can I say, I like box style cars!
You must be registered for see images attach
Following this thread, I started to assemble the usual suspects, Spyder glass headlight assemblies and an order to theretrofitsource for FXR projectors.
Summer is finally coming to an end in the PNW and headlights and rain-x are two things you should not skimp on.
One thing that differs from the OP is I tried to mount the projector as deep as possible in the housing. Note the holesaw saw below gives a snug fit to the "ring" of the projector. Eliminates the need for a shroud and looks more OEM in such a shallow housing.
Please keep in mind, as a post this, they are still sitting on my workbench. There are two hurdles faced and a risk with this application I have not tested yet.
First, lighting to the right and left of the rig may be cut off due to being recessed so far back.
Second, additional clearance is needed for the adjustment "basket", body mount, AND possible trimming to the radiator support. Waterproofing this system is TBD as the entire projector housing is outside of the headlamp assembly
. Further support/reinforcement of the projector will happen at this step.
Now the risk: You better drill straight or you will have a cross-eyed truck! The OD of the hole saw provides a very snug fit. My plan is to install the assembly without the glass lenses. Mark reference points for general beam aligment, uninstall, and epoxy the projector in-place. Using this method will allow me to get close to perfect, and use the factory adjusters to dial it in.
Lastly, I am exploring options like the OP mentioned to give this retrofit a more OEM+ look. Considering etching the high-beam or entire glass lens and polishing the projector pupil.
Here's my build in progress:
Follow the steps in the original post to disassemble the lights. Then find yourself a 2 11/16" holesaw :/
You must be registered for see images attach
Take a close look....
You must be registered for see images attach
You must be registered for see images attach
You must be registered for see images attach