Made a little more progress today.
Had to decide between a more "compact" light to mount directly on the front surface of the bumper (previous "post" pics) or what I knew would be a "good" light, but could require a little more complex mounting. Also battled with the diameter of the light to get everything to look correct and minimize the mounting of the front trim piece onto a curved area of the bumper when complete.
Decided on a good "name brand" light that puts out a nice beam and is small in diameter. Got those ordered today.
These will help immensely in positioning of the front trim piece on a flat area of the bumper, but it will cause some problems on the overall support due to length. They are only about 2 1/2" dia, but about 5 1/2" long.
The fix for the support will be to fab up a couple of pretty simple brackets which I will mount to the bumper bracket (it's the thing with 2 holes in it). Note the corrugated steel piece running vertically on the left side of the photo. A "low" mount will need to go thru that, a "high" mount goes above it. Leaning towards the "high" mount to simplify things.
Was hoping to have a design which did not require removal of bumper, but the lights will now have a very secure mount and "float" in the bumper hole ... these babies won't be bouncing and fluttering as I drive down the street.
Next step is to design the front trim piece and get those ordered. Concept for those is to make them look similar to the grill surrounding the main headlights (i.e. round with chamfers on the edges). I think I have eliminated the need for the canister sleeve due to the light selected and what I plan to do with the front trim piece.
Parts should start arriving early next week.
