| I am currently performing the Bosch E46 Retro fit on the JDM headlights and I am documenting it as I go so that others thinking about this project will have a better idea what exactly is involved. The retrofit is not complete yet but i have the Projector mounted so that it is still fully adjustble like the stock 300zx Projector. As the Retrofit continues I will be adding more photos and information so stay tuned. This thread will focus on the brackets needed to complete this retrofit, basically its the hardest part and where everyone hets stuck Here are the major tools i used to make the brackets:
Mitre/chop saw
hole saw 2 1/4" or 2 1/2"
File
sander or just sand paper.
Drill
Drill bits 5/32, 1/8, and 15/64
Taps M5x0.8, M4x0.7 The hole saw is the most important tool here! If you don't have one go buy one they are like 23 CDN from home depot or very close to it. I tried to cut the pattern out with a jig saw.... YEAH NO DEAL! It came out horrible! I also used a ban saw and a die grinder but the job could have been done without them. I bought an aluminum piece of angle iron 1/8"x1"x4' for $19.49
CDN after taxes. I then used a board that i bolted the alumimum and created a fixture to drill out the large grooves. I used a 2 1/4" hole saw. Now i did have to sand a bit at the bottom due to mounting alignment with the reflector. It wasn't alot, using an orbital sander or die grinder and its a less than a minute. For ease of installation i suggest using the 2 1/2" hole saw that way you have more room to move making the algniment a little easier. Once the groove were all cut out, i used the mitre saw to cut the individual pieces. I made sure the brackets i made were the same length as the stock 300zx projector that was there before so i would not have any issue later on. Using that same projector i marked the holes on the sides in the exact location and drilled with a 15/64 drill bit and then used the stock pin and retaining clip to bolt it in. This way you still have full adjustability as you did with the stock projector. Continue with the other side and attach that one as well to the black adjustment piece (as seen in the photos below). With this done take the reflector and mark up the holes. Make sure that the reflector sits striaght :) Drill the holes with a 5/32" drill bit. Take the M4x0.7 Tap and completely tap through the reflector as the holes only have threads half way. you can also tap the 4 holes you just drilled into the brackets or you can use nuts at the back as i did. Either way you have to tap throught the reflector so that the bolts comes throught the reflector and thrrough your bracket. I then used a M4x0.7 x 1" bolts and respective nuts to secure the reflector to the brackets. Once you have made sure everything is correct and straight take the pins out of the side of the black metal adjustment base. You will need to sand or grind down the sides of the reflectors so that you will not have any interferance problems. Once this is complete you need to mark one more hole to the top adjustment screw. Simple trick: using a paint marker, paint the tip of that screw and then mount up the projector to the headlight assembly and the bracket will hit that screw you've painted. Now you know where to drill using a 5/32" and then proceed with a M5x0.8 Tap. Once that is all done you can bolt the lens and reflector to the brackets and install back into the headlight assembly. Any question? you can add me to your msn if you like, email is padrinomacoretta@hotrmail.com. Here are some pictures 
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Bosch E46 Retrofit- PART 1: fabricating the brackets - 
