2015 Explorer Roof Rack LED Mount | Ford Explorer - Ford Ranger Forums - Serious Explorations

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2015 Explorer Roof Rack LED Mount

FireHat

New Member
Joined
December 29, 2020
Messages
1
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City, State
Vancouver
Year, Model & Trim Level
2015 Explorer XLT
I’ve searched high and low to find a thread discussing how to cleanly mount custom rear facing LED light pods but could only find forward mount, so I’ve decided to tackle this project on my own. I’m almost finished, just need to mount and wire, but I’ll post up my progress so far and as I go until completion.
Parts list:
1. Set of 70406BL Rough Country 6” LED pods.
2. Rhino Rack Vortex roof racks
3. 14 Gauge plate steel. (Light bracket)
4. 1/8” thick x 3/4” wide steel bar (attachment mounts inside track)
5. Assorted wiring and connectors
6. Rubber grommet
7. 3M adhesive wiring hold downs (keep the wiring nice and tidy)

Step 1.
Cut out steel plate for top and sides of LED pods. I notched the sides to fit nice and tight on the oval shape of the cross bar.
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Step 2.
Weld the sides to the top plate with mig welder and grind/sand down welds to make pretty.
Drill holes in the sides for the M6 bolts that mount the light in the bracket. Leave a slight gap on top of the light so it can still pivot.


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Step 3.
Cut out 4 x 2” strips of 1/8” x 3/4” steel to fit in the top track for the attachment point. Tapped 1 m6 threads into each of the 4 pieces.


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Step 4.
Placed bracket with light mounted, on cross bar to figure out where I wanted it to sit to ensure clearance for the light. Drilled 2 holes in the top plate for the m6 bolts that marry up with the 2” tapped track mounts.
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Step 5.
Primed and painted everything Matte black to match the colour of the roof racks. Mounted to cross bars. (Last picture has eyelets in outer mounting holes, added those for attachment point when tying down cargo on
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Step 6.
Next step will be to run wiring inside the cross bar and out 1 side, down onto roof and in through the back hatch with using existing factory holes in hatch area to keep as clean as possible. Will post progress as I get to it...
 
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peterk9

Staff member
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Elite Explorer
Joined
December 28, 2010
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City, State
Russell, Ontario (Ottawa area)
Year, Model & Trim Level
2020 Aviator Reserve
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VE3
Welcome to the Forum. :wave:
Nice job so far. Looking forward to seeing the completed installation.

Peter
 
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