Ok believe it or not but this isnt looking that difficult at the moment

First of all i will find some kind of pipe a little bit wider in diamiter as the nose cone of my HID globes and will cut 2 lengths to fit the globes. (see pic)

Then i think your gonna have to walk me through how much of a gap to make for the light to escape.

*EDIT* doing this will block like all the light except what is coming out of my correctly cut gap in the cylinder correct? I have a feeling this will make a hell change in beam pattern. It will be more of a solid bright beam yeah?

 

 

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You are on the right track.
But remember it is vital to remove the lens in order to get the best possible result.

By the way, how does it look under the HID bulb base?
How is the shield attached to the base?
Maybe you can remove the shields and make new ones? Could also use some parts of the old shield......

Again look at the Halogen bulb and see how the light is emitted from the Lo filament.
The shield that looks like a cup under the filament has a specific shape length and width.








You need to think how the light is emitted upwards from all sides of this cup in all directions and cut a hole that allows the same light pattern to be emitted from the HID bulb.
Then you need to look at each section on your reflector and see how light is reflected from that portion, how much, in which direction and how does the light pattern from that portion look like on the wall.
Which means that you need to block all the other light from the other parts of the reflector.
Once you have done one part then you do the next and so on.
So start by inserting the Halogen bulbs back and draw a line on the contours on each sides beam pattern. Mark the hot spots as well.
If you don’t want to draw on the wall place a whiteboard or tape some white paper to the wall or something.
Just make sure that your drawing stays at the same spot all the time.
If you have to move the vehicle then mark where you were parked.

Just one question, will me putting a cylinder over the HID globe produce more heat and shorten the life of the HID globe?

I have been playing around doing what you've said with those spare headlights i have ( the ones where the reflectors arnt the best ) but ya can still see where the beam is trying to get to.

I removed the lens and did the paper on the wall thing too trace a beam pattern. Also made a cylinder with the gap in the correct place but this is only made out of thick paper just to get the right set up..

Re your question: It all depends on how thick the pipe is.
All manufacturers i.e. Volvo, Lexus..... who have a HID reflector and not a Projector use a shield and it works fine without shortening the life of the bulb.
Just look at the Lexus projector I posted earlier.

But, of course if the pipe is like the ones used in the water pipelines then you will have a lot of problems.

By the way, I know that you already know this but the heat from the bulb will very easily burn any type of cardboard or thick paper.
So be very careful so you don't have to call the fire brigade.

Have you a couple of bear or Coke cans? Use them instead to make your shields from.

Also so you don’t loose track of what you have done, every time you make a shield draw the beam pattern on the same paper with a different colour and mark the shield with the same colour.
Soon you will see that you have gone too far and the beam pattern is too small. Then all you need to do is go back one or two steps and make smaller adjustments to those shields.

By the way, you may get a bit distorted beam pattern with your old reflectors since they do not emit the light properly.
Once you made a shield that gives you the best beam pattern possible, you may still need to do some minor adjustment when you use those shield in your new reflectors.

Sweet so were on track

I'll do my experiments inside as i have a 12V power supply, just wondering if this will be enough to power the HID's and which wires of the H4 plug need to have + and -?

While im downing this cougar n cola to get a spare can, thought id post some pics of the whole kit (or one side anyway). If i turn into a aliki holic its your fault mav's

- - - - - - - - - - - - - - - - - - - - -

I dunno wot them other plugs are for but they dont plug in anywhere and it all works well

1st step:

And yes my cutting is straight after 1 can

 

 

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Take it easy on the cougar n cola.
Here is a pic of H4.
Also a pic showing the difference between H4 and HID.

 

 

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Tried my best to get mine straight..

They look pretty even to me hey considerin the pic is on a little bit of an angle

What do you mean they look pretty even?
Are you referring to the pic showing H4 filament and HID arc?

yeah

Forgot to post the pic.

The bits marked in red are to the bits that need to be blocked.
However, the top part where the arrows are need to be tested with the bulb in the reflector and as I mentioned earlier tested with each portion of the top part of the reflector blocked.
I think that the Right side needs to be a bit smaller than the Left side.
I am referring to the beam pattern on the wall.
The only way to be certain on the shape of the cut is trail and error.

 

 

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how important is it to be blocking that bottom bit of the HID?

Any tips on holding the can section cylinder like?

I refer you back to the pic of the HID reflector on previous page. Second and third pics.
Take a very close look at the way Lexus nosecone looks like.
Now, remember that they use a standard D2S bulb.
Which has a following measurements.
Take those measurements and imagine where and how much of the bulb will be visible from behind the nosecone?

I have also attached a reflector from Volvo XC90.

Again take a very close look at the nosecone they used and you will see what you need to do.
Also bear in mind that their reflectors are much different than yours.
i.e. they have a lot of smaller sections which reflect the light in different angels in order to create a desirable beam pattern.
In your case we are trying to adapt the HID bulb to the focal point of your Halogen reflector.

 

 

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Ive got my 8000k kit in now and looks nice.But...
I noticed that one of the globes isnt lighting up properly,only the top half of the globe lights up.So im in the process of getting a replacement from the supplier.