by Vega2008 » Sun Apr 19, 2015 9:37 pm
Okay, so I have finished this project, and will include some pictures of how I did this in case anyone wants to take a look.
1st, I looked for a 5 inch round aluminum type can to duplicate the original turn signal lens shape. I didn't want to melt any plastic lenses or have any issues with the heat being added to the lower valance area. (last thing I wanted was a fire).
I found (online) an aluminum cake pan in 5 inch round x 4 inches deep made by Fat Daddies and bought 2 of them. I dropped my original turn signal lens into the pan's and traced out the lens pattern. Then traced out the opening in the bottom of the aluminum pan for the Fog lights I bought to fit through and used a hole saw to cut them.
I spent about an hour on each pan drilling out the holes for the fog lights to prevent warping them out from the heat. Ended up cutting a 4 by 4 wood post and screwing them into the bottom of the pan to hold the cans in a vice while drilling them out with a drill press. The tricky part was using an end cutter to trim the excess metal off of the pan to match my lens shape, once that was done, I spent a lot of time filing the shape to get it right. Once that was done I cut out the small access holes so the aluminum pieces could be screwed into the front valance where the bolt would go through the lens at the top in the front.
After that I made L shaped brackets that were drilled out twice each so rivets could be used to attach the brackets to the back of the can, and these brackets mount to the original holes that are in the valance to mount the original turn signal light housings. I didn't want to have to use nuts on the ends of bolts to screw the can to bracket, so I drilled and tapped the aluminum brackets so only a screw is used to mount them to the lower valance, no nuts are needed.
I used the brackets that came with the fog lights to mount the fog lights to my aluminum brackets. Only modified the top bracket to a z shape to allow for a drop of about half an inch so the fog lights would be in the center of the aluminum cans. I am able to adjust for up and down and side to side movements with this type of mounting so the lights can be aimed properly. It all fit together pretty well, I spent about 3 days making everything after getting home from work at night. The hardest part was all the filing and bracket work to figure out where everything was going to go. I'll let the pictures do the talking now, please note these are chrome faced H3 Running lights, the are SAE and DOT approved lights, and all you see is chrome until they are turned on. Looks kinda bichin if you ask me. I am moving the turn signals to the headlights so I'm not turning back at this point. I am including pictures with the lower valance off the car so you can see the installation easier.
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Last edited by
Vega2008 on Sat May 23, 2015 5:11 am, edited 4 times in total.