First off, the metal bar is suppose to be their. It's what is used in projectors to create the cut-off line. This is commen to ALL projectors and is SUPPOSE TO BE THERE. Do not remove it!!!!!
Also, DO NOT use 100 watt bulbs!!! Using 100 watt bulbs in housings ment for 55 watt bulbs with wiring ment for 55 watt bulbs will cause you to melt or headlight housing and ment the wiring at best and cause a headlight fire at worst!!!
Your crappy light output is likely due to the bulbs you are using. Not all bulbs are created eqaul. Many aftermarket bulbs are junk, especially those wal-mart/autozone "high performance" bulbs.
Get a good set of bulbs. They won't be cheap but are worth the investment. My first recommendation is PIAA Super Plasma GT-X's. Far and away the best Halogen bulb out there. Second I'll recommend Either Slyvania Silverstars or PIAA Extreme Whites. That's it...don't waste your money on any other bulbs..not other PIAA's like the "star white" junk they sell, not other brands. Stick with those 3 and you'll be fine. Read the sticky at the top of this forum. It explains a lot of this in detail.
AFTERMARKET BULBS: COLOR TEMPERATURE AND USABLE LIGHT OUTPUT