lzlegacy12,
I had similar trouble with the passenger side. In fact, I tried to force the fit at first and ended up breaking the upper mounting tab because the fit was so tight - it just snapped off because there was too much tension on it. All due to the metal bracket that is pushing on the high beam dust cover. I used some vice grips to bend the trailing edge of the metal bracket, and now it fits without forcing (I also fixed the mounting tab with a piece of sheet metal).
My U-bars are not wired as DRLs; they are wiring as the parking light. And I still had the annoying dim high-beam as my DRL, so I disabled the DRLs entirely. I plan to rewire the U-bars so they come on with the ignition.
All in all I really like these headlights, but there are some frustrations that may push me to modification.
1. The U-bars are not very bright. I may add some LED strips behind the bars so they are more effective DRLs and so they are actually visible in broad daylight.
2. The high beams are crap, and I couldn't get the driver's side aimed high enough before the reflector fell off the vertical adjustment screw. Now it's aimed at the ground. I will have to take it apart to fix it, and I may just put a set of bi-xenon projectors in the high beams (a bigger project that I don't want to tackle right now).
3. The turn signals are NOT visible from the side unless it's the dead of night, so no one directly next to me can see if I am signaling. I might add something in the corner reflectors so I have some side-visibility.
Other than that, I really love these headlights. Mostly because my D2S bulbs look GREAT in the "halogen" projectors, which really seem designed for HID.
As promised (though delayed), photos to follow in next post!