1: Yes, I cut about a 3.75-4 inch hole in the back.
2: FX35, I don't know about the size differences.
3: Actually I only used 2 screws, both screw into the reflector with a lock nut on the other side, and JB weld. The way the projector fits inside the reflector, more than two screws is really not needed, it's very tight.
4: The solenoid only needs a + and -, it is not polarity sensitive. When you turn on the high beams it sends 12v to the solenoid.
5: I'll try to get pictures shortly of what I trimmed off.
6: Yes, I used the OEM dust cap. The aluminum tape is just so the reflections in the headlight housing look better. If I did not use it, you could see the back of the projector (what is not covered by the shroud.) in the reflections. The bulb is the only thing that sticks out of the dust cap.
7: I have not used anything to seal up the back of the reflector. At this point I don't think it's needed because I was able to use the dust cap. I might add something once I finish working on the passengers side.
8: The way I mounted my projectors, I adjust my headlights just like I did before. There are no additional aiming screws.
I can try to do a write up on this and post it as a PDF, might take me a week or two as I have had a busy schedule lately. I might not have taken enough pictures as far as the steps go, because I was learning as I went along. You should be able to do it. Just PM me with any questions. I also have two extra reflectors. So I could sell you those to use. Thats how I did mine, I did not touch my original headlights until the projectors were mounted correctly on my extra set of reflectors. Just buy an extra beat up set of headlights off of
ebay. As long as the reflector is in good condition you're fine.