Sounds like your focal point of your light source is very small. A diffuser might help. Or even moving the point source of the light around some, if you can move it out of the focal point of the reflector, to "unfocus" it some. Using shims or spacers. Will take some experimenting to find the optimal point.
I use a Halogen 130/90 bulb. The 130 filiment is large, meaning only part of it is in the tight focus of the reflector. It lights up the road CLEARLY for a measured half mile - no "bars" in the light. No problem seeing a brown mule deer wandering onto the road for some distance. As long as I don't look away too much, can't overdrive the light even at 80. Though I'm pretty much never in that much of a hurry at night.
My 130/90 bulbs typically last around 3 years or so. With every replacement the headlight needs to be re-aimed. Indicates the filiments are not in exactly the same position with each bulb, though they all came from the same maker (and maybe lot, I bought them in a batch). I get them at Competition Accessories,
http://www.compacc.com/p/kuryakyn-replacement-headlight-bulbs. Brand is Kuryakyn. With such powerful, long reach lights, focus precision becomes an issue. When compared to wimpy bulbs.
