I did the conversion last night without taking out the headlights. Since I wasn't using my heavy duty harness due to several disappointing bulbs I swapped the wiring on that instead of the stock wiring.
I used my dremel to shave off the sides of the 9007 bulb instead of shaving those nubs on the headlight housing. What I did was stand up the 9004 bulb next to the 9007 bulb and look at the little slots for the nubs on the sides of the bulb housing. On the 9004 the slots are at the 12 o'clock, 4 o'clock and 7 o'clock positions. On the 9007 the slots are at the 12 o'clock, 5 o'clock and 8 o'clock positions. I marked with a felt pen where the 4 and 7 o'clock positions should be on the 9007 and used the dremel to shave off the excess plastic. I had to shave it twice to make the bulb fit. It was alot easier than pulling out the whole housing and shaving off the two nubs.
Btw my Sylvania Xtravision 9007's cost $15 Cdn apiece. I haven't driven at night yet but looking forward to see how its like.
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Originally Posted by Brudaddy
Sounds promising, BlackCat. Let us know how it is.
Some pics would be great if possible.
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I didn't take pics but here's a pic I just put together:
Stand up the bulb on a table top.When you look straight down at the bulb the small plastic tab sticking out at the base is the 12 o'clock position.
The yellow shaded area in the pic is the 7 o'clock position while the slot to the left of it is at the 8 o'clock position. The yellow area is where I dremelled the side flat to be the same depth as the nub. I then dremelled on the other side at the 4 o'clock position.
I hope thats as clear as mud!