Round LED tail light in a Square YJ

[JeepinMaxx]

I picked up some 4" LED tail lights at the Rally.  Nice set-up, but no template for cutting the hole in the tub?  Has anyone done this mod?  If so - what diameter circle do I need to cut in my YJ tub?  as they say measure twice, cut one time - you can't add metal  :wink:

 

[kevinc]

lots of writeups out there.  here's one..  http://www.links4jeeps.com/writeups/ledtaillights/

oh, you can always add metal.  welders are your friend.  HTH,

Kevin C.

 

[bigbadwhitey666]

Mine ended up Just around 4-1/4 .I just made a template and used a Jig saw.

 

[kakirubi]

Frank, what are you going to use for backup lights?

 

[JeepinMaxx]

BigBad / Steve - how do you handle the DOT required side marker lights, Licence plate light and the requirement for rear reflector and side reflector?  (The LED lights don't have a reflector built into the lens) ?  Thanks for the input

Frank

 

[cjshloman]

Frank for the plate use a product called lite'n'boltz  its a small lite integrated into a screw.   Bull


http://www.northernautoparts.com/ProductDetail.cfm?ProductId=1979

 

[JeepinMaxx]

Frank for the plate use a product called lite'n'boltz  its a small lite integrated into a screw.  Bull


http://www.northernautoparts.com/ProductDetail.cfm?ProductId=1979

Thanks Bull- already have a set on order.

Just need to find out what size hole saw to buy...

 

[massxj]

i have the lite n bolts on my plate and they dont work all that well.  you may want to put 4 lights on . they cause a lot of shadow  over the raised numbers on the plate

 

[bigbadwhitey666]

I still have to order some Lite Boltz . For now I just Bootyfabed a PLATE Light. For side markers ya could just get some reflectors.

 

[JeepinMaxx]

I'll be the 1st to say it... - Holy Old Post Batman  :grinyes:

Anyway since I started the topic - I can dig it up  :mad02:

I finally got around to doing this install today.  I bought a 4 -1/4" hole saw and drilled a test hole in a 1/16" stock.  The grommet seems to fit OK (tight fit).  BUT the LED light wont fit.  I'm glad I did a test run on some scrap 1st  .  I used a dial caliper to measure the OD of the light and it's 1.305"  So with a 1.250" hole - the light + the grommet should be impossible.  If I go with a 4.5" hole saw, will it be too big of a hole?  This LED kit came with no templates - so even if I use my body air saw or jigsaw - I don't know what diameter hole I need to make.  For those of you that did this project - how did you determine the diameter of the hole?  I appreciate the input.

 

[beaker]

If your cutting sheetmetal.  Drill it to the 4.25 and die grind the rest of the way.

 

[frankiev]

i was going to say use a dremel  with a grinding wheel on it

 

[MasterDrazhar]

Ditto on the grinding to finish off the hole Frank.

 

[JeepinMaxx]

Thanks guys for the input.  For the extra grinding - the 4.5" hole saw will net me a 1/8" larger hole...  :wink:  I'm Just curious how Steve/ BigBad and a few others measured for the cut..

 

[cjshloman]

Cant help ya...havnt done mine yet...but mine are hummvee lights...all kinds of weird cutting.

 

[yj-mike]

Frank,

I haven't done this, but I did something similar when I added the TJ style fuel filler to the YJ. Do like someone above said and use a piece of cardboard. Keep cutting the circle in the cardboard bigger until you have the right fit. Then use the cardboard as a template and draw it on the body.

Here is a pic of what I am talking about:

Start cutting.

 

[JeepinMaxx]

Got it done today. It was an all afternoon project - however I took the time to solder all the connections.  After researching some truck/trailer websites - they all spec'ed a 4.5" hole.  So I did end up using a 4.5" hole saw - made it easier to install, however you could get away with the 4.25" and filed it down for a tight fit.

1st Removed the old tail lights and marked up 2.25" from the bottom of the factory hole and center-punched it for the hole-saw drill bit

Then I taped off the area to keep from scratching/chipping the paint

The implement of destruction  :mrgreen:

No going back now 

On a YJ you cut very close to the inside tub because the gas filler neck doesn't let you cut any lower (on a TJ you probably could)

Next install the grommet, wire it up, and slide the LED light into the grommet

Here's a shot of them with just running lights

Here's a shot of the brake lights

I still need to do something for back-up lights...

I'll wait until it gets dark and check to see if the LEDs have a reflector and see how the license plate lite n bolts work...

Well - the license plate lights work - barely  :evil: but at least you can say I have them :wink:

I'll need to add some reflectors in the rear to be legal...

 

[toyworx]

Looks nice Frank.

 

[frankiev]

great job frank it looks realy good  :smile:

 

[Rubi13]

Nice work Frank...looks awesome...great instructional write-up too