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It sounds like the housing is restricting the headlights from turning, but has anyone tried cutting the housing? I understand the desire for everything to remain "looking" stock, but this should be more than that...this should be about accomplishing a goal! This is just the prototype stage...once we figure out the kinks, it should be no problem to either create a custom housing that fits this mod perfectly, or is a completely new setup that one can purchase outright.
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