[wagonman76]

That's something I'll have to play with. I'll probably just build the LED board, cut open a headlight case, and hold it outside at different depths in the case to get a rough idea. See how it compares with the headlights of my other cars. Then make an adjustable bracket to mount the LED board to the back of the case. Then when done I can aim each LED board so the brights and dims line up correctly to each other on a wall 25 feet away. Then there should be no more adjustment needed to the LED boards. I would think most of the light should go directly forward, since with incandescents you shine them on a wall to aim them and they do make distinct lit areas.

I think if we get something close it should be fine. There is quite a difference in headlight visibility between different vehicles.