The more expensive way (maybe) would be to buy an already sealed and ready to go projector such as the HL68137 90mm Low Beam Lamp with H9 bulb from Hella. These run about $60 for each projector.
www (dot) rallylights.com/hella/90mm_modules (dot) asp
The European ECE version is more desirable due to the H7 bulb and the cutoff pattern but they cost about double. So the American SAE is the better choice. I believe you can get a Silverstar in the H9 size and the cutoff pattern can be changed if you feel the need. I have a ton of info on this light. Here's a great page of info on it:
http://faqlight.carpassion.info/hella-90mm/
(moderator, this is a FAQ, nothing is sold here)
I know at least two guys who've done this:
TXHorns281
http://www.afbforums.com/index.php?&...CODE=12&CID=47
and skytower31:
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Keep in mind that if you have an extra $300 laying around just about any of the above projectors or housings can be fitted with an HID bulb and ballast. Although using an HID bulb in the stock housing isn't recommended due to the light scattering and possibly blind oncomming traffic. Projectors are the way to go if you want HID.
I have an "on again-off again" project of making some fixed lights for my LS1. I'm making them completely from scratch. The lenses, filtering, venting, adjustors, everything except the projectors which I mentioned above were the E46 units. I plan to use modded H7 bulbs (Silverstars) at first and then later on upgrade to HID. I'm also converting them to bi-xenon with custom solenoids. That way both high and low beam will be HID. It's a hell of a thing to do, but I've learned a lot. So if you have any questions, let me know.