So I got my Hella 500's hooked up and I am trying to aim them, looks like the driver side beam is egg shaped and the passenger side is circular. I tried adjusting them and its still the same. Whats going on?

 

Look at the pattern on the lense. If they are different then someone mixed them up in the box. The driving lights look like ovals and I beleive the fog lights have a more circular pattern.

 

some one at the factory must of mixed them up

 

Check the mounting tabs on the bulbs. If one is bent, it will throw off the light pattern.

 

So yeah, I checked out both lights and they appear to be identical. I pulled each bulb and they both look straight. Now they're blowing fuses and wont turn on. Damn.

I hate electrical stuff!

 

sounds like there could be a problem with the reflector or a mfg fault with the lens... as to the blowing fuses sounds like you pinched a wire when you re-installed them. If you want [have] to keep them I'd open them up again and check for the pinched wire and either replace or repair it. But if you can still exchange them I'd go that route, tell the store you only tried the one time though and that the light pattern is wrong.

actually now that i think of it the lamp that has the 'round' pattern could just have the lens and or reflector 90degrees out of true try rotating the one or other [if pos.] a quarter turn this might solve the problem.
Hope this helped Aviator

 

sounds like you forgot to put back on the ground screw

 

Not sure what you mean when you say "pinched a wire". I'll try the turning of the lense but I think it can only be installed in one position only.

Both the lights are grounded. Do you think that the ground possibly isnt good enough on one of the lights thus throwing out a different or weaker light pattern?

What is the light pattern supposed to look like on the driving lights, a circle or an oval?

I am referring to the shape of the light when shining them against a wall.

 

by "pinched wire" I mean one or more of the leads coming off the lamp may have been caught between the reflector and the housing when you put it back together and has been partially cut through causing a short to ground which would cause the fuses to blow and the lights to not work.