charger Mon Nov 30, 2009 10:26 am
here we go, after cutting the back off the light, the plastic chrome rim comes off, make your pattern of the light you choose, trace it on plywood of mfd and cut the shape out with a jigsaw without damaging the outside of the shape, cut a strip of steel 1 inch wide, insert into the plywood shape and bend it to conform this shape, cut to length and weld the ends together (french insert??) , next take a piece of plate wider and longer than your insert, trace your shape and cut out the center,weld this plate to your insert, measure and cut out the lens to fit, next i made a light bucket just a hair wider than the insert, drilled and die grinded a hole for a light socket, this is how it fits together, you put the lens between the flat plate and your light bucket, drill holes through all three and fasten with screws, now if your lens is not 100% flat you can also use a heat gun to straighten the lens, cut a hole in your roll pan the same size of your insert, give yourself a little gap and weld in place, the packing plate of the insert can be trimmed and welded the rear box beam, spray paint the inside of the light bucket a bright silver, install a regular or led bulb and your ready to go! as you can see i didn`t quite finish the welding, ran out of wire!!!
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