Installation:
Drill two 1/8" holes into the external A-pillar cover where you previously made your marks with the template. (De-burr as necessary.)
Lay the spotlight mounting bracket gasket in position.
Place the mounting bracket over the gasket and attach it with the included self-tapping metal screws.
NOTE: It's very possible that the included 1/8" screws may not be long enough and thick enough for a good "bite" into the A-pillar. I encountered this problem when I realized that the mounting bracket had a very slight amount of play to it. So, I ended up using inch-long #10 screws instead.
It's absolutely
imperative that the spotlight mounting bracket is attached to the A-pillar as solidly as possible. Not just for the sake of a secure mounting, but the mounting bracket itself will
also serve as a drill alignment guide for your 1/2" hole once it comes time to drill it.
You
do not want that mounting bracket off-axis, even in the
slightest for this reason alone. If it
is, your 1/2" hole may end up someplace inside your FJ where you didn't want it!!
Slide the included drill alignment guide sleeve into the mounting bracket and secure it with the flat-head side tensioning screw.
Using the drill alignment sleeve as a guide, begin drilling your 1/2" hole as straight in as possible. Periodically stop and check your progress, as well as let the drill bit cool down.
Eventually, your drill bit will appear precisely at this location on the inside of the A-pillar. (Due to the angle of the drilling, yes, the inside hole in be somewhat oblong in its shape.)
The inside hole will be somewhat jagged, so it will probably be necessary to de-burr and file the edges of the hole. Use a coat of touch-up paint to cover the exposed edges of the hole.
Temporarily replace the plastic interior A-pillar cover, and run the 1/2" drill bit through the hole by hand (bit removed from the drill). Nudge the bit up against the back side of the plastic cover until a dimple appears from the outside. This will be your "mark" for cutting a hole in the plastic for the spotlight shaft to protrude through.
Again, remove the plastic interior A-pillar cover and use a combination of smaller drill bits and a Dremel tool to shape a clean hole that will accommodate the spotlight's handle shaft.
You may have to repeatedly replace the plastic cover to determine exactly where the shaft will be coming through.
Remove the drill bit and alignment sleeve and insert the spotlight shaft from the outside of the truck all the way until the swivel base meets the mounting bracket. Then secure the spotlight within the mounting bracket with the side tensioning screw. (Remove masking tape from the exterior A-pillar cover.)
This is what the spotlight shaft will look like in the interior once the spotlight is inserted.
Replace the side curtain airbag tether strap and the grab handle mounting bracket.
Slide the interior A-pillar cover over the spotlight handle shaft and reposition the cover into place.
Slide the rubber filler gasket onto the handle shaft all the way to the interior A-pillar cover. Then slip the retaining ring into position and secure with an Allen wrench.
Replace the grab handle.
Re-install the control handle by gently sliding it onto the handle shaft and rotating it until you feel the shaft's notch line up with the inside of the control handle.
Once installed, the control handle should be at the same angle as the head of the spotlight itself.
Now you can relax . . . . the hard part is over.
(Continued in the next post . . . . )
