Hella 500's on custom brackets install (warning- lots of large pics!)
 

So, I decided I wanted some driving lights, but not in exactly the same spot that everyone else puts them. So I decided to eschew the outmotoring brackets, which are really nice IMO, and custom fab some at my friend's house. It was actually quite easy, and cost me about $80, and that includes the money I paid for the lights. (rotf) Here is how it was done:


The two pieces involved are two L-shaped brackets, with two backing plates, one for each side.

http://gallery.morker.us/cache/Drivi...56.JPG_700.jpg




The backing plates are inserted inside the bumper support, through the air cooling holes and bolted to the L-brackets.

http://gallery.morker.us/Driving+lig...0/IMG_0055.JPG




The bumper is then modified slightly with a dremel tool to cut small notches about 3 inches wide. If you screw this up a little bit, it doesn't matter because it can't be seen at all when standing in front of the car.

http://gallery.morker.us/Driving+lig...0/IMG_0049.JPG
http://gallery.morker.us/Driving+lig...0/IMG_0050.JPG


Switch panel is then drilled out to provide a hole for the new toggle switch. Thanks to Gloves for the idea, on this thread https://www.northamericanmotoring.co...gle+switch+mod

http://gallery.morker.us/Driving+lig...0/IMG_0041.JPG




New toggle switch is inserted, third from left, after cutting out some extra room inside the switch bank.

http://gallery.morker.us/Driving+lig...0/IMG_0044.JPG




Here is the finished toggle switch in place.

http://gallery.morker.us/Driving+lig...0/IMG_0046.JPG
http://gallery.morker.us/Driving+lig...0/IMG_0062.JPG


And here is the finished car, after lots of fussing around with wiring.

http://gallery.morker.us/Driving+lig...0/IMG_0063.JPG


And here is my mini sitting the next morning with it's friends, including our rally car that can be seen at http://saabrally.com

http://gallery.morker.us/My+Mini+Coo...0/IMG_0073.JPG

thats cool!!!

Nice job! Those will work a bit better than the Outmotoring brackets. Having the lights mounted higher will help you see better. That being said I really like the look of the Hella 500's on Outmotoring brackets. Mine will go on this spring.

Now tell me about that Saab. Is that your rally car. I see a cage & skid plate. Not to mention those wonderful lights. :thumbsup:

The saab is not mine. My friend, the same one who helped me build these brackets, built the rally car himself, top to bottom. More info can be found at http://saabrally.com There is too much to list here, and I can't remember it all anyway. Prepare to see us take the 1st place M1 class eastern states rally championship this year! :nod:

I think yours looks the best out of your friends:thumbsup:

Well of course it does. :nod:

Nice placement, sharp. Nice Saab rally car...I am a reformed Saab owner.

As am I. I have a 97 900s sitting up at my parent's house waiting to be sold, but it got rear ended and needs a little bit of work. That's what I got my mini.

I just sold my 95 900 SET, it was a great car. I have been using it as my winter car w/snows since the MINI came home.

We are moving to Asheville, NC next week, the last thing I need is 3 cars at an apartment.

So my friend in PA who helped me make these, said he'd make some for more people if enough people wanted them. We figure they'd be very cheap, less than $50. Any takers?

What is the material, stainless or aluminum? (he asked, hopefully...) Looks like a good, slick idea.

I believe the material is plain steel. It may be stainless, but we grinded, brushed, primered and painted them anyways. I'll double check with my friend.

Sounds cool either way, nice design! Any jiggle?

How stable are the lights? I can't stand dancing lights, just hate them. I was also wondering if they were stainless steel.

Many moons ago, before some NAMers were born I drove a 1967 Saab 96. Three Cly, 2 stroke & 4 on the column. Ring Ding Ding....was the sound it made. :grin:

The material we used was plain steel. If we start selling these, we will probably consider switching to SS, or using regular steel and painting them like mine are.

Also, there is absolutely NO jiggle in the light whatsoever that I have seen in the week I've had them on the car. They are as stasble as can be. I don't know what the results would be with a bigger, heavier light, but I'm pretty sure the brackets are stiff enough. I'll keep everyone updated as we decide what to do.

how about some more pictures of your friends bouldering wall :wink:

nice job. and i like your workbench too. :grin:

Hmm, sneaking around my gallery, are we? :nod: