Ok. I have posted a little about my problem here and hidplanet and I wanna do a full post with the learning process I did the past few days.
And my results and problems.

Picture #1
This is 7ft from my garage door. The drivers side is the problem.



Picture #2
This is passenger side only from 7ft away looks decent to me.



Picture #3
This is drivers side only from 7ft away. Crazy blurry, not even and over laps.



Picture #4
This is the car parked 20ft away from house I am of course closer!



Picture #5
This is at 20ft away just passenger side. Seems really good. Can even see light on fence to the right.



Picture #6
This is at 20ft away just drivers side. Sloppy and burry and not even.




Now

I have added spacers to driver side lens no change. Just got worse far away or close.
I added spacers to lens housing to move lens further from shield and it just got worse.

So I moved the lens in the drivers housing to match perfect the orientation of the lens. No change.
I swapped the passenger lens housing over to drivers bowl, no changes.
I swapped the passenger bowl over to drivers still no change.
I swapped the passenger bowl and lens housing over to drivers side, no change.

The whole time passenger side remains same.

So lastly I decided to swap the bulbs just for kicks, and no change. I moved the bulbs around a little no change.


So I now ask. What is there left to rule out. Ballest and whole headlight housing.

Drivers side height adjustment screw is broken but I adjust it to the correct height and add a small zip-tie to keep in place.
I am lost as what to do. New or used headlight housing. Even before TSX-R swap the drivers side was sloppy.

Please any advise would be great. I'm lost as to what's wrong here.
When I test projectors out in my hand with a LED flash light they seem 100% perfect.


Sorry to post again about this I'm really lost.

The cut-off shields are both the same and perfectly match up. Nothing on the projectors seems wrong. Seems like one connected to ballest and installed in housing my frustration begins.

Please someone help.

Bulbs are pinkish color and each bulb has a white milky film on outside of bulb. Not too much in the capsule in middle like I read.

My friend has 10 of the bulbs says all his are like that too.



So whats next for me to try. If you need pictures of projector housing here is a link to a DIY for TSX-R install.
DIY: Headlight Removal, TSXR lenses & Painted Cutoff Shields (Pre-Facelift)

Thanks in advance

 

Congrats on doing the swap, I've done a couple of these my self, just not in my audi yet.

The TSX lense on the drivers side, how clear is it in comparison to the passenger side? Is there any fogging or warping in the glass?

And out of curiosity where did you order the kit/parts from?

I've bought all my kits from The Retrofit Source online: headlight upgrades for all applications

Any installation issues I called them up and they helped me out nicely.

Let me know the condition of the lenses and we can go from there.

 

Here is more I posted on hidplanet.com

Housing is a little bit less clear then passenger side but still look really good after the 3M kit on housing lens. I ordered the premium tsx-r lenses from trs.