I am going to invest in some cheap ebay projector headlights and throw some Hella 60mm projectors in there to replace the crap optics.

Since these will just be 'project' lights, I dont really want to cut up my stock lens to fit onto the ebays. So I was wondering if I could make a lens for the ebays by heating up a sheet of ABS plastic and forming it them.
Does this sound doable?

wow, its not even worth doing it. just retrofit some fx35s in your stock headlights

I'm just wondering if it WOULD work, because if I go the ebay route, I really want to stay away from cutting my lens.

Regarding the fx35 retrofit...I am still considering that, but I am on an extremely tight budget right now. If I did a retrofit into the stock reflector, I would probably get low beam projectors/bulbs and use my aux lights for highs to keep it cheap.
Another question, would I be able to make a wiring harness for the single beam projectors and control them just like stock (without the highs)?
If so, I assume that would be much easier to make since I wouldn't have to deal with the extra relay for the high beam solenoids.(I have seen your wiring diagram)

thanks

i would use polycarb....good for thermoforming