hmmm all this work just for some light on the trails? I have switched out my stock headlight bulbs with Sylvania Silverstar ZXE Xenon bulbs. What a difference! My wife also has an 07' FJ Cruiser like mine so we parked them next to eachother to see the difference of our headlights. I would say mine are atleast 3 times brighter. I purchased the new bulbs at a local shop for 60 bucks which is cheaper than the KC 7" headlight set I am planning on using for my 79' FJ40 to switch them from the sealed lights.
Again Easier is not what I was looking for. This project is a PITA so far, but the result hopefully will be a better housing then is currently available.
This will do 3 things. For those that want to run stock lights, it will give them a better quality pattern and more light than from the stock "Buckets". For those that want to run H4 upgrade lights like your self (I used to special order 85/100 or 100/120 off-road bulbs in my jeeps), you can and get even better results from those changes. And finally for those that want to run an HID insert bulb (me these days - sick how much light comes out), this will give them the ability to run those without the issues we all have with bleaching of the reflectors and poorly focused beams that just piss everyone else off.
For those that still want the inserts, I say go for it, but I can't see them lasting for a long time based on the quality of the material I saw in the stock buckets that they depend on to hold them in alignment.
Has anyone added windshield mounted lights on their FJC? I have KC mounts and Black Magic lights but not sure if I want to drill holes in the windshield upright until I know someone else has already done it without major problems. I am only thinking of doing this for 2 real reasons....1. long range light 2. add the look of being a police vehicle along with my Transformer Barricade decals.
P.S. be sure you get the local law enforcement office and highway patrols okay IN WRITING before installing any decals to your vehicle that may look like you are trying to "impersonate an officer"
As far as your other question, there are a couple of posts about adding police lights and such, and a great idea one had for making the mounting plate on the small panel below the 'A' pillar. As far as that goes, I think I have that covered. I have LED light bars pointing in every direction, and am about to even put in the rock lights so I can see a little better on the close-encounters stuff at night.
I do have to say from previous experience though, the roof mounted systems give by-far the best light angles and definition for night-time off-roading. And if placed right (a bit behind the roof line to keep light from flooding the hood and blinding you - Demellos roof light bar is and EXCELENT example of how to build this right), you can see the contours of every obstacle with great detail and clarity. The pillar lights tend to be better for long-range focused light beams. If they are not focused, they always seem to reflect off the hood and body, and cause all kinds of nuisance with the eyes at night.
Just my .02, but like I said, this isn't about cheaper, or easier. It is about being able to use a tool I know works better, and have it last a LONG time.