Well, this is the headlight mod mid-project update for what it's worth.
The Halo bulbs had two of the alignment tabs line up but the third was off by about 1/2". I need to figure out which one is interfering and grind it off. The backs are made of plastic but the lenses are glass. All the chrome plating is inside the bulb so the outer portion of the back of the bulb is ok to grind on. Once It is removed I'll just wrap the bulb bracket in saran wrap and set the bulb in place (oriented properly of course). Then squirt some epoxy into the gap where the tab is missing and let it set up till dry. That should make a tab on the bulb that fits the bracket perfectly.
The other main item of concern is that these bulbs are slightly larger in diameter than the original bulbs. The trim rings will NOT fit over them without modification. What I am doing is cutting the existing joint on the trim rings and then using part of a spare trim ring to fill the gap. You will need access to a spot welder or know someone that is VERY good with welding thin metal. Below is a pic of the trim ring where I split it. The gap to be filled is about 1/2" or so.
Also, on the back of the clear lense bulbs there are some protrusions that interfere with the bulb being able to sit in the bucket. I took the grinder to one of those and it fits in there fine now. I'll have to do the saran wrap and epoxy trick to it as well because these bulbs don't have ANY alignment nubs on them at all.
Other than that, it's a straight forward swap. You can use the existing headlight bulb plugs to plug into the H-4 bulbs. Just check the existing wiring to verify that the wires are going to the correct pins. For the wires to operate the halo rings, just wire them into the parking lights or a switched power source. Whichever you prefer.
If you plan on doing the relay mod, these H4's will work just as well as the regular bulbs for that.
For the Driving light mod I plan on doing...
I'll let you know how it goes when I get there. It will be run through a dash switch and a relay on a completely seperate circuit.