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I'm just finishing installing a pair of Piaa pencil beam spots above the bumper and a couple of pairs of cheapie lights below the bumper. It has NOT been easy - I've probably spent 3 weekends on the job already and will need one more to finish the interior wiring!
Firstly -- in my bumper there were a couple of holes pre-drilled on the back side of the bumper in the perfect location for installing mounts. I had a couple of brackets custom fabricated (I didn't take pictures - sorry) - to enable me to mount lights both above and below the bumper. I attached the bracket with substantial sheet metal screws - they appear to be holding up OK.
The lights above the bumper are pretty easy - the lights below were tougher. I cut out the horizontal fins in the grille below the bumper EXCEPT in the center section (watch for the airbag sensor) and was able to open up enough space to get some small driving lights in - I actually tried a pair of Hella 550s but the space was SO tight -- and bulb replacement would have required removing the lights and re-installing them - so I went for smaller lights with front access to replace the bulbs.
The lights are relay switched so I had to find a place to mount a fuse block and several relays - I've got all that crowded in in front of the radiator (alomg with a set of air horns) mounted on a piece of 1" angle aluminum behind the grille. Everything painted matt black for invisibility.
I was concerned about air flow restiction but we have just had a week of 95 degree weather and no problems.
Switch location in the cabin was also a problem - I wound up using 3 tiny single pole, double throw toggle switches mounted between the two seat heater switches in the dash and mounting LED indicator lights to the left of the radio. The toggle switches allow me to have the driving lights: 1. switched by the hi beam switch, 2. off, and 3. switched on an ignition line.
The line feeds throgh the firewall behind the fuse panel.
I'll try to get a few photos up soon.
posted by 216.110.194...
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