Wow, what a chore! Removing the lense wasn't even the hardest part. Removing it without breaking a tab or two I think is impossible. Also, popping out the reflector bowl snapped half a ball retainer. Luckily it still holds in well with the other half of the retainer still there.
Sanding down the OEM bulb socket base was easy and only took about a minute each on my belt sander.
Now the horrible part is aligning the headlights. You essentially need to put the back half in the truck and bolting it in. Takes forever to tweak. Then you must tweak again after tightening the projector bolt.
Now the most horrible part is resealing the lens to the body of the headlight assembly. I cleaned out as much of the permaseal as possible and put a butt load of butyl rubber seal down. I hope that stuff holds the lens on over time.
I'm happy with the results, but don't feel like the assembly is as sturdy as it was in OEM fashion. I'm sure it will hold up though. Good thing that there are some really great retrofit places about 4 hours from here.
Here are some pics. The cut off line is straight, I'm parked on an inclined driveway at an angle.
Morimoto H1 projectors
Orsam 4300k bulbs
Morimoto h13 relay
Amazon purchased butyl rubber
2016 F450 Platinum FX4 CC LWB
2016 Chaparral 360IBL Fifth Wheel: 15,500lbs
GONE - 2011 F250 FX4 6.7L Lariat Ultimate