Here are each of the steps and some information that may be helpful.
If you are lucky enough to have a DC power supply, test the halos before installing them. If you do not have a DC power supply, connect the leads to the car battery and test them. You don't want to get everything installed only to discover a bad ring and have to break open the headlight assembly again!
1. Remove front bumper (~ 45min - 1hr) -
(
http://www.mazda3forums.com/index.php?topic=41782.0)
The tricky part here is finding the screws in step #3 (I didn't have the pic)
and I wasn't able to unclip the foglight wire so I unscrewed the entire foglight assembly (4 screws). I just had to do this on one side.
http://www.digitalguy.net/gallery/main.php?g2_itemId=128
http://www.digitalguy.net/gallery/main.php?g2_itemId=122
2. Remove headlamps (~5 min) - (5 screws each iirc) Pretty straightforward
3. Take out all bulbs (~2 min) - Don't touch the bulbs w/ your fingers.
4. Put in oven @ 200 for 10-15 mins (If you are paranoid like me, check on the assembly every couple minutes) Make sure you put the assembly on a baking sheet! None of the plastic will melt unless you set it directly on the heating coil. I went conservative and baked them for 10 minutes.
5. Pull out and separate the lens from the housing. (~2 mins) - Use oven mitts to pull out the assembly. It helps to have one person pull the assembly apart and another use a flat head screwdriver to gently pry open the clips.
Do this for one side at a time but do them both before proceeding to the next step.
*** You will want to minimize the amount of contact with the inside of the headlamp assembly. I did not use gloves but if I were to do it again I would probably go that route. ***
6. Silicone the rings into proper areas (~4 hrs) -
This was the most frustrating part of the install for me. The low beam rings sit nicely inside the reflector...
(
http://www.digitalguy.net/gallery/main.php?g2_itemId=176) Be sure to apply the clear silicone glue to the side of the halos that come in contact with the reflector. (ie. Look closely at where the halo makes contact with the reflector before applying the silicone.)
Here is a picture of the ring on the high beam reflector...
http://www.digitalguy.net/gallery/main.php?g2_itemId=173
Don't use tape like I did! Use electrical ties to stabilize the ring. Not only would the tape not hold the ring against the reflector, when I removed the tape, it would disturb the curing of the glue.
I used a dremel to notch a small hole in the housing for the low beam wiring otherwise the wiring would be pinched. The high beam ring wires should not run between the reflector and housing otherwise you'll sever the wires.
7. Clean up the housing. (~5 min each housing)
Hopefully you will never have to take the assembly apart again, so be very thorough! Wipe off any dust or fingerprints with a microfiber towel.
8. reheat in oven for another 10-15 mins @ 200. Use gloves to remove the assembly from the oven
9. Reset the lens back onto the housing. (~10 mins)
Run all of the wiring into the high beam hole as shown in step 13 of the howto. Make sure all of the clips are seated properly.
(After heating in the oven, I applied silicone all the way around to make seal more waterproof, but I don't believe this is necessary.)
10. Reinstall lights (~2 mins)
11. Reinstall headlamps into car (~5 mins)
12. Reinstall bumper (~30 mins)
13. Wiring. (~1 - 2 hrs) -
I extended the wiring from the kit to reach to the fuse panel in the engine compartment. I grounded the inverter at the battery ground and ran the positive wire to the fuse panel. I used the independent fog lamp modification howto to wire these into the fuse panel. The halos are controlled by the fog lamp switch on the left hand side of the steering column. (
http://www.mazda3forums.com/index.php?topic=11730.0)
Ultimately, I'd like to add a switch next to the DSC on/off switch to control them.
Here are some more pics...
http://www.digitalguy.net/gallery/main.php?g2_itemId=2290