ready to install my aux lights/radio bezel, what else do i need?

[LONO100]

hi all, i got a pair of pro comp 6x9 lights that i plan on installing in front of my cargo basket's wind screen. i designed a set of brackets that will bolt to my crossbar and hold each light right in front of my wind screen.

being that i have a sport trac, i was able to go to the local pick n pull and get a radio bezel out of a 2nd gen explorer and a second light switch so now i will have a very factory looking switch for the aux lights as seen in rebel's sticky
http://www.explorerforum.com/forums/showthread.php?t=320489

here is a list of materials i have, including materials i have at my shop that will help with the install:

-2nd gen explorer radio bezel
-a second switch
-2 pro comp off-road lights 6x9"

-aluminum (for custom light brackets)
-all of the wiring i will ever need in every gauge and color
-various ring terminals, spade terminals, push on terminals

i have almost every tool under the son, a bridgeport mill, a TIG welder, and a machine shop at my disposal.

for anyone who has made this conversion, or has installed aux lights on their explorer, please let me know if im missing anything, or please leave any tips, info or opinions. thanks in advance everyone.

 

[willindsay]

Looks like you've got all the parts you need. Only advice I've got is solder and heatshrink all the connections. The double wall heat shrink tubing is the best IMO.

Good Luck

 

[LONO100]

Thanks, I think I forgot to get a relay still not sure how I'm about to put that. I will be soldering with nice heatshrink too.

 

[LONO100]

So I fabricated some simple brackets for the lights, mounted them onto the roof basket, and got my radio bezel to use the factory light switch, and I've got a shop just waiting for me to wire it all up. My last question is, where should I place the relay? Would it he best served somewhere near the battery? Or should I put it under the dash? Any help or suggestions would be great. Can't wait to post pics of this project.

 

[willindsay]

So I fabricated some simple brackets for the lights, mounted them onto the roof basket, and got my radio bezel to use the factory light switch, and I've got a shop just waiting for me to wire it all up. My last question is, where should I place the relay? Would it he best served somewhere near the battery? Or should I put it under the dash? Any help or suggestions would be great. Can't wait to post pics of this project.

It's really just personal preference. The only thing the position of the relay really affects is the length of the wire from your switch.
I keep all mine in the engine bay. Just make sure it's easy to get to so changing it won't be a pain.

 

[01STrunner]

Along for the ride. You always have quality mods and I'm sure this'll be no different.

 

[LONO100]

That's a good call. I think I'll keep it in the engine bay so its easy to get to. I was thinking about putting it somewhere inside the dash behind the bezel, but that might be a pain to get to if I blow the relay. As noted, I've documented the whole process with pictures. I'll do the full write up as soon as I finish it up. Thanks guys!

 

[LONO100]

so i spent this morning at my shop attempting to wire up my lights. i noticed that the light brackets i had previously made for the lights werent as burly as id like them, so i ended up making some thicker ones from scratch which took up a good portion of my morning. once i got those done, i had to coat them with truck bed liner which took a while to do. then figuring out the routing for where and how the wiring would reach the battery cleanly took a little while. after some soldering and connector crimping i was ready to hook it all up and then i realized i didnt paint up the new radio bezel i just picked up at the yard. i forgot to cut the harnesses out, and i didnt have any push on connectors that fit onto the ford factory light switches so i think ill have to go back to the pick n pull and get the little harness that fits onto the switch and then splice my wiring into the wires coming out of the harness. i really thought i was going to get this done, but this is going to take some time. hopefully i get it done by may 17th, thats my big off road trip into the tahoe forest. first of the season.

 

[willindsay]

Just a thought I don't know what lights you're going to be using but if they are expensive ones I'd go with a bracket that will hold it solid but will bend so that if something hits your lights hopefully the bracket will just bend out of the way and not smash the light. Then all you gotta do it straighten the bracket or replace it.

 

[LONO100]

well, i tried to make some brackets that would in fact do that, but they bounced whenever i hit bumps when i tested them, so i made some thicker brackets that i dont think would bend. its ok, the lights i bought are 6 x 9 100w pro comp explorer lights that i got for just 40 bucks a pop, so they arent too expensive. im also pretty confident that where they are placed, i should be able to avoid hanging them up on stuff. ill post pics as soon as im done with this project.

so i routed most of the wiring, i just need to hook up the relay to the switch which im currently hamstrung on because i forgot to get the little harnesses from the pick n pull when i got the factory switches. im going to try to get this done by tuesday.

 

[LONO100]

This light install is more involving thank I thought. Its taken me forever to get all of that rubber off of the radio bezel and now I put some pretty good scuffs in it so I'm gonna have to do more wet sanding than I thought. I had to make about 3 sets of brackets until I was finally happy with it and now I'm trying to find a way to hide the wires. I got the relay hooked up and now I just have to solder up the switch to the wire going to the relay and add a ground. Hopefully I can get this done by tonight after work. I'm pretty happy with where its going so far and I'll post pics as soon as its done. I'm hoping to make it look as factory and clean as possible.