This is why I littered TWLive with pistures the other night. Sorry about that guys but I hope this is worth it.
First off, I had 3000k HIDs in my stock fogs. I got an AllPro bumper so I ended up selling the stock fogs and HIDs. I went with the PIAA 510 for the AllPro and couldn't have been more dissappointed when I flipped the switch for the first time.
That got me going...I searched a lot for a write up on converting the PIAAs to HID. I found (1) thread that gave me the basic ideas but wasn't as detailed as I would have like it to be. Therefore, I went at it and successfully converted my PIAA 510s to HID. Here is the write up!
Starting with the stock, out of the box PIAA 510. I removed the rock shield. Then you need to loosen the two Phillips head screws on either side of the housing. Do not remove them completely as there are retaining clips that will fall off.
I used the DDM 35w 3000k kit. I also did my Hellas at the same time but there is already a write up for those. Test the HID bulbs before you start!
Next you remove the lens from the housing. Mine came apart with no problems, however you may need to gently pry apart with a small screwdriver, making sure the gasket goes with the lens.
After doing so, clip the connectors on the ends of the wires and pull them through the grommet.
Press down on the clips holding the factory H3 bulb in.
Remove the bulb.
Next, you will need to remove this shield pictured. The HID bulb is 1mm too long to fit into it.
You will need to grind down these rivets with something. I chose to use a flapper wheel on my angle grinder.
I then used my spring loaded punch to punch the rivets out. A center puch and hammer will do the same thing. No Hee-Man swings!
Now you need to remove the sheild from inside the lens. It will not fit through the bulb basket so this will have to be removed. Feel free to do this earlier on in the process. I used a pair of needle nose pliers and bent the tabs holding the basket.
Time to go fishing. Who doesn't like fishing?
Gently remove the sheild, trying not to marr up the reflective surface in the lens.
It should now be blown out with compressed air or a firm breathe to remove debris.
Time to put the bulb basket back on. I started bending the tabs with the pliers but finished with a small flathead screwdriver and a hammer, WITH THE LENS SITTING ON A VERY CUSHIONED SURFACE!
Everything back inside and ready to install the HID bulb.
As with the light itself, you're going to want to snip the connectors off and pull these two wires through the grommet.
Insert the bulb into the basket and secure it using the retaining clips. Be certain to put the bulb in the correct way, one side has a square notch and the other a round notch.
Test the HID again!
With the lens taken care of, it's time to modify the housing. Find the center of the housing and use a punch to mark and get ready for the drill bit.
Using a vise to secure the housing during drilling, do not tighten too much, just enough to hold it. I used a 1/8" bit as a pilot hole.
Now drill the hole out to 7/8" using a step drill bit. I used a 3/4" and it was VERY tight, I got lucky, you may not. Play it safe and drill to 7/8".
Clean the burrs off! Now it's time to assemble.
Slide the wires from the bulb through the housing and fit the grommet.
Pulling on the wires at the same time, slide the housing and grommet onto the lens and tighten the two Phillips screws. I used a little grease on the wires to make pulling them through the grommet easier.
Install back into bumper. I decided to mount my ballasts using 3M double sided tape.
Good luck to everyone who attempts this. I hope it helps. I know there are some guys with aftermarket bumpers who are very dissappointed in the brightness of their PIAAs.
Disclaimer; Everything I did will void the manufacturer warranty on the PIAAs. Do not attempt if you are not comfortable with your abilities. I take NO responsibilities for you destroying a $160 pair of lights.