The first thing to do was cover up the squirrel finders. Most halogen projectors have something called a "squirrel finder" which is a narrow flap in the cutoff shield that allows light to go above the cutoff shield. It's not usually a problem with dimmer halogen bulbs. Since I'm using HIDs, I sealed the flap closed, to prevent glare to other drivers.
The upper wide opening is the area that the light comes through. The small rectangular below it is the squirrel finder opening. Because we're shooting this through the lens, the image will be inverted, which is why the opening is on the top.
I put the bulbs in and fired them up for a trial. As you can see, I missed a tiny slit in the squirrel finder, but I later filled it in.
Now, through a bizarre sequence of events, I ended up with two projectors and one cutoff shield. So, I had to fabricate another out of aluminum sheet. I went crazy with my power drill, dremel, and a file, to get this
Updates coming soon.