Step 10: Cutting in Recessed Light Pods
Just like the Winch Port/Fairlead setup, this is optional.
LIGHT PODS
I chose to create recessed 'light pods' for two driving lights. If you choose to do this, you'll need some pipe slightly larger in inner diameter (ID) than the outer diameter (OD) of your chosen driving lights.
First, cut yourself two lengths of pipe (I used a bandsaw here), which will allow you to recess your lights slightly, and will give you somewhere to mount them. I used about a 4" long piece of pipe on each size, with an ID that allowed my light room inside (including some wiggle room).
After cutting your pipe for the pod, chalk a line onto the front plate of your bumper, using the light pod light as a stencil (do the left and right pod).
Use your cutting tool of choice (again, I used a plasma here) to cut both holes using your marks. Be conscious that you will be welding in the light pod pipe, and that will come back a bit toward your truck. be sure it's not going to interfere with existing bodywork/etc.
After you cut the holes, slip your pipe joints in the hole as a test fit. The cleaner your hole you cut, the less you will have to make up with welds to cover you mistakes. You can see my plasma cuts are sloppy...so it took me more time to fill in with weld.
Once you like the setup, weld the pipe permanently into the holes you prepared. You now have a nice recessed light pod setup.
I used old pipe I had laying around. Avoid using rusty/mill scaled pipe if you can, and use something shiny and new to ensure good welds, and a good clean setup.
LIGHT PODS
I chose to create recessed 'light pods' for two driving lights. If you choose to do this, you'll need some pipe slightly larger in inner diameter (ID) than the outer diameter (OD) of your chosen driving lights.
First, cut yourself two lengths of pipe (I used a bandsaw here), which will allow you to recess your lights slightly, and will give you somewhere to mount them. I used about a 4" long piece of pipe on each size, with an ID that allowed my light room inside (including some wiggle room).
After cutting your pipe for the pod, chalk a line onto the front plate of your bumper, using the light pod light as a stencil (do the left and right pod).
Use your cutting tool of choice (again, I used a plasma here) to cut both holes using your marks. Be conscious that you will be welding in the light pod pipe, and that will come back a bit toward your truck. be sure it's not going to interfere with existing bodywork/etc.
After you cut the holes, slip your pipe joints in the hole as a test fit. The cleaner your hole you cut, the less you will have to make up with welds to cover you mistakes. You can see my plasma cuts are sloppy...so it took me more time to fill in with weld.
Once you like the setup, weld the pipe permanently into the holes you prepared. You now have a nice recessed light pod setup.
I used old pipe I had laying around. Avoid using rusty/mill scaled pipe if you can, and use something shiny and new to ensure good welds, and a good clean setup.
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