"Factory style" recessed fog lights in stock bumper (development stage pics)

[SwissArmySuv]

Hi Boys and Girls,

Starting the next project: Adding "factory style" recessed fog lights into a stock bumper.

Some of you may enjoy the project, so I'll post some details as I go.

I drive in Northern Michigan, Minnesota, Canada, etc on fishing trips and at night and during inclement weather, fog lights help - especially for spotting deer, bear, etc.!

I like the looks of "top surface" bumper mounted and "bull bar" mounted lights, but I have (2) issues with these for my application:
1) I pull a boat and I want every bit of air flowing through my radiator
2) fog lights need to be mounted low for them to work best for a low broad beam

Anyways, I am not planning on changing my front bumper so I am going to do an "in bumper recessed" mount and here we go.

After doing some "pondering", I am going to mount them in one of the "black" areas of the bumper below (cheapo photo editing):

lights high


or lights low


The install advantage goes to the "high" because I would not have to cut into the steel bumper support in-behind the black plastic and weld in some "replacement" strength. The performance advantage would go to the "low". Not sure which I will do yet.

I have looked at hundreds of different lights to use. Here are a couple of them:

Ford Focus


Generic


Focus version looks good but is about 4 5/8" OD (too big for available space). Generic has steel body and real glass lens and all necessary wire, but harder to mount. Will probably go generic and do a custom mount, also like its ruggedness.

Will probably make external trim rings for the bumper to make it look correct when I cut the hole into the bumper. Probably will turn down some plastic or aluminum on a lathe to make the trim rings.

Did not realize this until yesterday, but look closely at the bumper lights ... they even have little "external" rings. Oh well, I guess Jeep beat me on this one!


Here is where I stand:
1) found a guy with an extra factory bumper I have coming to experiment with
2) ordered a couple of "Tacoma" switches yesterday
3) hopefully will have lights ordered in the next day or so
4) will start fabbing up some parts in the next couple of days or so once some of the "stuff" starts arriving

Will keep you posted on progress.


Note: This project is currently finished and kits are available at this time to anyone.

Here are some quick links to the primary topics:

Installed pictures of the completed project:
"Factory style" recessed fog lights in stock bumper (development stage pics)

Kit cost/payment/shipping details:
"Factory style" recessed fog lights in stock bumper (development stage pics)

Possible sources for Hella Lamp Kit:
"Factory style" recessed fog lights in stock bumper (development stage pics)

Additional related wiring harness post:
fog light harness install (lots of pics)

Current kits available as of July 9, 2007:
0 > sold out

Notice: I will be away on vacation July 10th thru July 18th with no internet access.

If you have questions you can PM me or e-mail me before or after the above dates.

[Sun Fusion Cruiser]

Good luck. I look forward to seeing the finished project.

[SwissArmySuv]

Update:

Don't laugh, just found the fog light housing I needed.
Spun aluminum, with flange, 3.64" ID, black anodized.

Marine aluminum cup holders!



Sometimes you do not have to re-invent the wheel, just a little re-application.
One step closer.

[jkwhite]

Looks like a good project. Keep us updated with pics.

[tnegiet]

I like the looks of the higher set better...good luck!

[Prof T]

Be nice to see the real thing. Excellent idea.

[bleen-bleen]

both ways look great. good luck. you ought to work for toyota because it is sad fj'ers have to add stuff that should be factory.

[Taz]

I vote for the lower one so they will be more functional fogs. What is the point of having fogs if you don't mount them where they are most effective? Now if you just want the wider beam pattern of a fog then that is a different story.

I don't encounter fog that often here but the wider fog beam is nice when turning off the main road onto a snowy side road at night.

[thugasaur]

wow swiss your quite ingenious good idea on the cup holders

[SwissArmySuv]

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.