Hey Dibble,
just a suggestion for you...one of the reasons that I blacked out my housing besides me wanting too was that; when Rich installed the projector into the housing, on the bottom of the gatlin shroud the chrome reflection showed what was behind the shroud. This was on the bottom of the projector and you could see a little bit behind. It wasn't really noticeable until you put your head up against the front of the headlamp and looked at the bottom part specifically.
Rich took some pics for me and sent them to me, but as I'm writing from my new computer, all of my pictures are still on my old laptop which unfortunately is riddled with a stupid virus from a corrupted song I DL'd. But as luck would have it, I managed to save one pic to my photobucket.
This was taken from Rich before he painted it. If you look at 6 o'clock position, you can see what I think is the washer or something that holds the projector to the shroud. I'll try and see if I can yank the rest of my pics from my old computer. Just though i'd try and let you know before you go ahead with your project. Let me know if you need anything else!
-Kaleo