Well after some testing with fitting and alignment of the headlights with the original headlamps that the projectors came in, I decided to make my own projector headlights. So I went to the store and bought 3 1/2" hole saw, 2 5/8" hole saw and some aqauarium sealer, 2 H4 wiring pigtails.
First off, I marked where my first intial drill points would be. You do not have to take off the lens of the headlamp but it would makde it a hell of a lot easier. I drilled my holes with the lens still in. Then the hole saw did the rest. After the first hole (2 5/8") was made I used a fine sandpaper and got all the left over plastic pieces off the cut area and made it a smooth surface. I also pulled out the light deflector inside the headlamp out because you will not need them.
Then I made my second hole (3 1/2") and I repeated the same thing as the first step.
I made the holes 1 1/2 inches away from each other and the bigger projector on the outside part of the headlight and the smaller projector on the inside part of the Legacy headlight.
Pull the projector lights out of the Impreza headlamp that the porjecotrs came in. Take off all the wing nuts and all the threaded studs out. Unscrew the holder on the ion projector. Run your wires through to the back of the stock Legacy headlamp. Once all the wires are fed out through where the old 9004 bubs go into, put in your lights.
I found out with the 3 1/2" hole was a tight squeeze to get the bigger projector in. You have to trim a notch for where the threaded studs used to be. I just used a sharp box cutter and I trimmed it. After that was done, I put in my second projector, which was kinda intersting because you can do one of two things...put in the the whole projector and make it flush (pain in the butt) or put it on the outside with only the chrome ring sticking out. I did it sticking out and it looks good.
Now fun with aquarium sealer...I used the sealer used lttle. Using very little as possible, I outlined the bottm of the chrome ring using the sealer and I also did the regular light/sealed projector. After a couple of layers of aqaurium sealer and trimming extra sealent.
Now this protects your headlamps from the elements and is very waterproof. If you have your projectors coming from the inside (when you remove the lens of the Legacy headlamps), apply the sealer from the inside around the cup of the projectors. But make sure all your connections are secure. I put electrical tape around the dual spade connectors and around the Halo wires to make sure it wouldnt move.
After the sealer has dried enough so it wont pop out or slide out, you can put the lens back on the headlamp housing using the same sealer. Now you can mask the projectors and paint the headlamps a color of choice. In my case it was glossy metallic silver grey with several coats of clear coat. Make sure you use medium-fine grit sandpaper before applying the paint unless you are using a primer, to ensure that the paint sticks to the lens of the headlamp. Add a few coats and clear coat and let dry for 24hrs or heat dry.
Connect the wires to the H4 pigtail harness from your 9004 harness. Make sure you have at least 1-2" of wire left if you want to revert back to 9004s. Connect your new harness to the the provided H4 projector harness and you're done. You now have custom projector headlights.
I will get some pictures up of the finished project. I will completing my project tomorrow and I will bolt it up to the car.
Remember: I did this on my own. I am just sharing the info so it might be useful for other people. If you break your own part(s) from using my instructions I am NOT liable for any property that has been destroyed, destroyed or miswired.
Have a nice day!I hope you all find this useful!
jkjk. looks good. but could we get some better pics.