Will you be using the same projectors Kaleo has in his retro?
I potted a pair of Denso "thin" ballasts with that same MG epoxy,was worried that curing them in my oven would render it unsafe for baking purposes afterwards,so I let them cure on my dining table for 48 hours
. I kept an eye on them for the first hour or so to pop any air bubbles that surfaced.
I'll be potting a set of modified Bosch ballasts soon,not sure if I want to keep them hard-wired at 70 watts to power the DL50s in my offroad lights or make them switchable from 50 to 70 for my headlights (also DL50).
Dibble does your truck have DRLs or not? The non-DRL headlight systems do not require a diode,lowbeam and highbeam have a common 12v positive. Ground the ballast relay(s) at chassis,not the lowbeam ground (which loses continuity when highs are on).
EDIT:found a pic of one of my potted Densos
http://i275.photobucket.com/albums/j...t/DSC00023.jpg