By: Brent Rooks
Tools Required:
-Soldering Gun with solder
-Dremmel with very small cutting wheel attactment
-Philips and Flat tip screwdriver
-Ratchet
-10mm socket
-Wire strippers
-Drill
Parts required:
-1100 MCL LEDs (2)
-560 OHM resistor (2)
-Wire connectors (10)
-Ground connectors (3)
-15 AMP fuse (1)
-Rocker switch (1)
-Fuse connector (1)
-Wire 16 gauge (2 pieces at 15 feet)
-Plastic mini blind adjuster rods (2 rods at approximately 3 feet
-Zip ties (1 bag)
-Clear silicone adhesive
-Super glue
-Sandpaper
-Electrical tape
-Shrink tubing
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CAUTION- Be advised of ALL oven settings indicated,
as an auxilary light is not exactly the cheapest part
to replace. Team Sol WA does not accept any
responsibility for any damage that is incurred while
performing this mod. This is to be used as a reference
and may take some trial and error process to achieve
satisfaction.
NOTE- This mod may take up to 48 hours to perform.
*************************************************
1. Remove front bumper.
2. Remove auxilary lights using 10mm socket.
3. Remove all plugs, wires and screws from aux lights. Strip it
completely down to just the lens and the plastic backing.
4. Pre heat oven to bake at 275 deg.
5. DO THIS TO ONE AUX LIGHT AT A TIME. Place light on a cookie sheet
with tin foil. Set light in oven once the oven is at 275 deg.
6. THIS STEP IS VERY IMPORTANT. Set timer for 7 minutes. Once 7 minutes
is up, CAREFULLY (will be VERY hot) pull aux light out of oven and use
flat tip screwdriver to pry apart the lens of aux light from the
backing.
7. Repeat process for second aux light.
8. Cut plastic mini adjuster rod with dremmel to lengths measuring 9 5/8
inches. You will have some extra left over. Save it, you may need it as
it will take some practice making precise cuts in them later detailed.
9. Place one rod in oven set at 275 deg for 10 minutes.
10. HAVE YOUR AUX LIGHT LENS READY. Pull rod out of oven very carefully
(again IT WILL BE HOT) and place rod into aux light lens forming it into
the backside of the lens face all around the edge. CAUTION: You may have
to hold there for a moment and it will be very hot. If you do not have a
good fitting on the plastic rod, place back in oven to soften back
up and remold to fit. NOTE: With a correct measurement of the 9 5/8
inch molded correctly you should have room for fitting of the LED.
11. When your satisfied with how plastic rod will fit into the back of
the lens, remove plastic rod and use the dremmel to make small incisions
around the backside circumference of the plastic rod. The incisions
should be made with a tiny cutting wheel approximately 1/8 of an inch
apart. May take some practice, hence the extra plastic rod noted
earlier.
12. Use the Clear silicone adhesive to glue the plastic rod in the back
of the lens. Keep the rough side (side with the cut outs made in it) to
the back of the lens. Also, keep the small gap for the LED on the bottom
of the lens. You will need to let this cure over night.>
13. Once the silcone adhesive has cured, place the aux light and backing
slightly together, then place back into the oven set again at 275 for 4
minutes this time.
14. Pull the light out of oven and firmly press backing and lens
together
15. Use a drill to CAREFULLY make a hole in the backing of aux light on
the lower portion for LED and wiring to go through. NOTE- May take a few
trys to get the correct sizing of hole.
Wiring
1. Connect wire from positive battery terminal to 15 AMP fuse/fuse
connector.
2. Continue running this wire through firewall port located directly
below battery to positive lead on the switch. NOTE- Switch can be placed
in slot directly behind emergency brake.
3. Run wire from ground end on switch to ground location on frame.
4. Run wire from source lead on switch back through same firewall port
and route wire through engine compartment to the center of the front
bumper location.
5. Cut 2 wires of equal length measuring approximately 3 feet.
6. Connect these 2 wires to the supply wire.
7. Solder 560 OHM resistor to end of both of these wires.
8. Solder 1100 MCL LED to resistor.
9. Sand the end of LED very carefully just getting the tip of LED using
sandpaper.
10. Use electrical tape to fully seal the soldering of the LED and
resistor.
11. Super glue end of LED (just the tip) and very carefully slide
throught the hole in backing of aux light and place end of LED in the
gap in plastic rod.
12. Use Clear silicone adhesive to fill hole in back of aux light and
secure the wiring in place. NOTE- Allow the silicone time to cure.
13. Reassemble.
By: Brent Rooks