Auxilliary reverse light project - Anyone have advice for drilling reflector lenses? Running wires? (1 Viewer)

[CharlieS]

I'm starting a project where I'm putting small LED lights (Rigid Ignite reverse lights, flush mount) in the reflectors in the rear bumpers for supplemental reverse lighting. They are mostly for setting up the camper in the dark, not day to day use. I will have them wired up through my switchpros.

The installation instructions for these lights require a 1 3/4" hole to be drilled, plus the mounting screws. I have a new hole saw on it's way, along with a spare set of lenses from eBay. I've done a bit of googling, but any advice you can offer would be appreciated.

I have some sheathed 16 gauge tinned marine wire that I will hook these up with (using delphi connectors). I don't feel the need to run these inside the cab, since the path is from the rear of the engine bay to the rear bumper. I hope to find a path that is protected under the body. Before I just wing it, can anyone share their favorite route to run wires front to rear?

 

[chilibit]

Inside the frame?

 

[SQRRRL]

I'm starting a project where I'm putting small LED lights (Rigid Ignite reverse lights, flush mount) in the reflectors in the rear bumpers for supplemental reverse lighting. They are mostly for setting up the camper in the dark, not day to day use. I will have them wired up through my switchpros.

The installation instructions for these lights require a 1 3/4" hole to be drilled, plus the mounting screws. I have a new hole saw on it's way, along with a spare set of lenses from eBay. I've done a bit of googling, but any advice you can offer would be appreciated.

I have some sheathed 16 gauge tinned marine wire that I will hook these up with (using delphi connectors). I don't feel the need to run these inside the cab, since the path is from the rear of the engine bay to the rear bumper. I hope to find a path that is protected under the body. Before I just wing it, can anyone share their favorite route to run wires front to rear?

 

[CharlieS]

SQRRRL,

Every mod I want to do, it seems like you've already been there.

Mine is still in kit form:

I want to put it here (in the upper half of the lens, the bottom seems to be a reflector):

I'm waiting for the spare lenses I bought on eBay to arrive. That way, the mod can be undone.

 

[wiseinvestor]

SQRRRL,

Every mod I want to do, it seems like you've already been there.

Mine is still in kit form:
View attachment 2236184

I want to put it here (in the upper half of the lens, the bottom seems to be a reflector):
View attachment 2236187

I'm waiting for the spare lenses I bought on eBay to arrive. That way, the mod can be undone.

Sorry if this is obvious but you can pop those off by removing two nuts from under the bumper. You will see what you are dealing with once you get them off. They look from the back to be actually molded for use as a bulb housing... maybe in another country. Interesting idea. Is the hole saw for the back side of the housing or are you thinking about drilling the round hole in the face of the housing and then sticking the rigid light into the hole?

 

[CharlieS]

Thanks, that was my understanding as well. I was thinking about using the hole saw to drill a hole in the outer lens, and surface mounting it. I'm open to other ideas though. I got two used lenses on eBay to experiment with, rather than attempting it on the original ones. If that doesn't work out, I will try to mount them on the bumper itself, but I'd prefer not to do that, if I can find a way.

 

[wiseinvestor]

I think it is a cool idea. I have no experience with this type of project so keep in mind my thoughts are uneducated. I think the back of the rigid light is square and the round hole might be to big and very close to the drill/screw holes. Another option would be to attempt to cut a square hole. Also have you thought about washers or some type of backing plate for the screws to go threw to provide more strength. The light won't sit completely flush from the outside once complete and I would hate to brush into it and crack the whole thing loose.

 

[greenseaman]

Will be following this thread! I could really use some more light while backing up especially with tinted windows!

 

[SQRRRL]

Will be following this thread! I could really use some more light while backing up especially with tinted windows!
[/QUOTE
Try LED reverse light bulbs as well. Nice kicker on my 2013. License plate LED bulb hinder back up camera performance.

 

[CharlieS]

I also have LED bulbs in the reverse lights, but have been underwhelmed. I had PFran bulbs on prior rigs that worked much better. The ones I have are better than stock incandescent, but are not awesome.

I used the SYLVANIA 921 T-16 W16W ZEVO LED White Bulb, per a recommendation here on 'Mud.

I'd be psyched to try others if you can share a recommendation!

I used some 194 LEDs in the license plate and haven't noticed any issues.

 

[SQRRRL]

I don’t recall what brand I have. Perhaps Phillips. Helps a little but nothing ground breaking. Good luck with you mod. Hope it turns out well. I never thought of doing that.

 

[dubyahard]

Have you seen this? New reverse lights for a GXL - A saturday afternoon project.

 

[CharlieS]

Have you seen this? New reverse lights for a GXL - A saturday afternoon project.

I hadn't seen that, but it looks like a good way to go, and is very stealthy. I may try to track down some of those NLA lenses.

 

[CharlieS]

Spare lenses arrived in time to do the project over the weekend. I'm still seeking advice about drilling the lenses and wiring routes.

 

[Hoosier Daddy]

Looks like a fun project! I was tempted to try this exact thing a while back, but I'm trying really hard now to keep my truck as stock as possible. I'll just live vicariously through you, I guess.

When I had envisioned this project, one of my thoughts was to paint/plastidip the lens flat black around the LED housing, leaving the reflector section unpainted.

 

[eatSleepWoof]

I'd be super worried about cracking the lens while drilling it.

Does anyone know whether heating up the plastic (low temp, oven) would help minimize that risk?

From an aesthetics point of view, I think the lights would be better suited for the bumper. Coincidentally I have a set of those same Rigids sitting in a closet, waiting to be put to use. Interested in seeing how this turns out!

 

[CharlieS]

I'd be super worried about cracking the lens while drilling it.

Does anyone know whether heating up the plastic (low temp, oven) would help minimize that risk?

From an aesthetics point of view, I think the lights would be better suited for the bumper. Coincidentally I have a set of those same Rigids sitting in a closet, waiting to be put to use. Interested in seeing how this turns out!

We'll see how it goes. Plan B is to put the original lenses back in, and install the Rigid lights in the bumper. I'll post as I try this out.

 

[CharlieS]

So, it turns out that this isn't terribly difficult. With a new hole saw, and sharp drills, it went pretty smoothly.

In case it is helpful to the next person through:

I marked the center with a sharpie, drilled a very small pilot hole, followed by a larger hole, then switched to the hole saw. I monitored and varied the speed depending on how it was cutting. The lens can melt rather than cuts if there is too much friction, so I kept speeds low. Once the hole was cut, I used a deburring tool to clean up the edge of the hole. I installed the Rigid into the light housing, marked the lens mounting holes with a sharpie, then drilled the two holes for the mounting screws. I drilled a hole in the back of the unit for the wiring to exit.

I'm trying to decide whether I want to use sealant on the faceplate to lens junction, and whether I want to bother with a grommet for the back.

I do have one concern remaining with this whole idea, and that is heat dissipation. I don't know if running these lights in an enclosed housing is going to create a heat issue. I will try a test on the bench before installing them, just to be sure. I'll hook one up, turn it on and monitor the lens and housing temperatures with a IR thermometer.

One thing I'd emphasize is that I have some very sharp twist drills and I bought a new hole saw for this project (so it was also very sharp). I think sharp tools are important in this job because they cut cleanly as evidenced by the "chips" I was seeing. Sharp bits don't have as much of an issue with friction that can melt the lens material.

 

[SQRRRL]

So, it turns out that this isn't terribly difficult. With a new hole saw, and sharp drills, it went pretty smoothly.

View attachment 2237051
View attachment 2237053
View attachment 2237054

 

[Eric Sarjeant]

Easy peasey. Technically illegal because you should have a reflector in case your vehicle is disabled or parked on the road, but hey, we like to do cool things too