HID FOG Lamp Install
The following is a How To on converting the standard H3 bulbs that come with the Mazda 6s Sport bumper fog lamps to HIDs. The assemblies... Show more are not designed for HIDs so some minor modifications are required.
(Note: The following How To is for the Brightstar HID kit only, some or all of the steps may not be necessary for other HID kits. The Brightstar HID kit goes by many names, check the pics below to see if your kit looks similar to the kit in the pics.)
Take apart the assemblies and remove the stock bulbs. In the assembly there is a small tab that is designed to hook into the H3 bulb and hold it steady, while the screw on the other side holds it from the other side. The problem is, the HID bulb base is much thicker than the stock base, so you will have to bend the tab back and widen the hole. Make the hole just big enough for a small screw to fit in it.
Insert the HID H3 bulb into the assembly and screw the screws into the holes. You may have to slightly carve out the cutout in the base to get the screw to fit.
Cut a small rectangle out of the back of the top of the housing. The rectangle should be no wider than necessary to fit the base of the HID bulb through. Also, make sure to cut it parallel to the screw holes in the assembly. This will ensure the rectangle is in the correct orientation in relation to the H3 base.
Locate the rubber grommet that held the HID bulb in the original packaging. Cut the interior of the grommet so that it is wide enough to fit around the base of the HID bulb without expanding.
Run the wires from the HID bulb through the opening in the assembly base and press firmly on the base while screwing in the screws. As you can see, I much improved my installation technique from the first one to the second one.
Personally I connected everything and took the pictures below. However, in reality you probably want to go ahead and mount the fog lamps in the car, run the wires, and connect the switch.
Optional: If you want to be able to aim the fogs when you are done, you will have to take a few extra steps. First I widened the holes in the fiberglass, purchased 16mm long x 6mm dia screws, and two 3" C clamps. I drilled two holes in the C clamps where they were aligned with the housing and ran the 6mm screws through the holes into the housing. This gave me the capability to aim up or down (by loosening/tightening the screws), and right/left (by loosening/tightening the C clamp). The final product is below: Show Less