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Old 11-28-2004, 11:44 PM   #1
Rapid_Roo
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Default The Ultimate Auxiliary Lighting and Mount Thread

We have a dozen threads on this by now. I think its about time we consolidate all the post and pictures so that someone interested in the subject would a place to come and compare the different methods of mounting auxiliary lights. I'll post mine in a little bit, along with some other ones that I have found over the course of the year that I have been totally addicited to idea of having more light.

Things to post would be pictures and specs on the lights, your purpose for the extra wattage and how you came about coming up with your design. Links of where to get the bar or materials would be nice. And for the techno-sapiens among us, diagrams for modified or all original wiring would be a bonus.

This is open to lights mounted on bars, pods, custom fab'd tabs, velcro or just replacement of the stockers with something else.

thanks for participating,
RR
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Last edited by Rapid_Roo; 11-29-2004 at 11:47 PM. Reason: I got my wish, there's a link in the FAQ.
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Old 11-29-2004, 12:58 PM   #2
Rapid_Roo
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Default Here is my contribution

Where it started

I knew I wanted some more light output for normal driving. I got a pair of PIAA bulbs for the headlights and some 110W Ultrawhite PIAAs for the stock fog lights. This was good put I wanted a little more. So I got some PIAA 004x. I went with some smaller driving lights because I didn't want to alter the look of the car too much.



This whole time I was doing night time road rallies. With each rally I was learning a little more about road rallying as well as what I needed to have in terms of lighting. I ended up re-wiring the fog lights to I could keep them on whenever I wanted. This helped but I was still needing more light into the corners. One of the things about doing a road rally at night is that you need to cast light down the road as far as you can so that you can see signs and clues as soon as possible, but also you need to be able to see into the corners especially tight ones, like the ones you would find in the moutains or canyons.

This triggered my quest for something with a very wide despersion and long coverage. I stumbled upon the Hella 4000s in the "Cornering" pattern. It looked like it should do the trick. The problem was then, how do you hang a 9.5" light that weighs 11 lb. each? I had seen a couple cars with their lightbar but wasn't convinced that it would fit or even handle the wieght. I started hanging out at meets and taking to John from Rally Innovations. He asked me what I wanted, what I planned on doing with it, and if I wouldn't mind running a sticker on my car. Being part of the anti-sticker crowd, I was reluctant. I looked at the sticker and thought, heck if I am going to run one, I want it to look different. So I fired up CorelDraw and Photoshop and turned out another one, this lead to doing a full car for them. But I still didn't have a bar to hang the lights on. So I asked them if they would be willing to modify a bar to fit the lights. So in trade for the work on graphics John said he could do anything and that he just need the lights. So I bought them and dropped them off at RI.... he was shocked. He didn't realise how big they were or how heavy. Well after a month and many phone calls and faxed sketches back and forth we came up with this.



It is mounted to the frame under the car and to a custom bracket that Rally Innovations made that connects to the bumper beam. We tried to make it look as much like his current product line. Although this was to be a one-off, there was talk of making a production piece out of it. But after much deliberation John had decided that this was to be the only one like it from his shop.

It worked out well. I did a complete wiring harness that allows me to switch all the lights on at the same time using the lighting stalk. I made a custom box and harness myself.



The light coverage looked like this. It goes pretty deep into the night, and is fairly wide.



But I still wanted more. I ended up switching the lens from "cornering" to "driving" , swithced the stock fogs to Hella 500s in a driving pattern and then adding the PIAA 004xs back on and aiming them at 45 degrees. This was cool, but it still wasn't perfect....

...I bought four Hella FF75s, two in driving and two in fog. I also got some Osram Yellowstar 100W bulbs for adverse driving conditions... more on this when this phase is done.

<more pics to follow... stay tuned >

Materials
Rally Innovations Custom Lightbar
Brightstar HIDs in stock headlight housing
PIAA 004x (PIAA 110W superwhites)
(formerly in the grill, now in the grill of my LX)
Hella 4000s ( Narva Rally bulbs: 130W )
Hella 500s ( Narva Rally bulbs: 130W )
-coming soon-
Hella FF75 <driving> ( Philips +80% competition bulbs)
Hella FF75 <fog> ( Philips +80% competition bulbs)

Sources
www.rallyinnovations.com
www.rallylights.com
www.suvlights.com
www.scoobymods.com

Last edited by Rapid_Roo; 11-30-2004 at 01:04 AM. Reason: added pictures
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Old 11-29-2004, 01:57 PM   #3
brunetmj
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Default

Here is a pair of Hella micro lights mounted on my STI

http://www.tirerack.com/accessories/hella/micro_de.jsp

Here are some PIAA driving lights installed under the grill of my 02 WRX

http://www.sportsimportsltd.com/pilig10plats.html



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Old 11-29-2004, 02:57 PM   #4
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here is my sad atempt and sold the inner lights, now i just have some hella amber fogs in teh stock location.
i just had to post before the heavy hitters chime in
Shane
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Old 11-29-2004, 03:30 PM   #5
DDMan
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More pics to come later, Just wanted to get a post in. You all have bascially seen it.

Here is a pic of mine, no holes...just mounts to the lower radiator support and the lower "U-brace" (both under the car). The lights are Lightforce RMDL170's (6").


Last edited by DDMan; 03-12-2007 at 11:11 PM.
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Old 11-29-2004, 04:38 PM   #6
Psydotek
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Default

Quote:
Originally Posted by PARANOID56
here is my sad atempt and sold the inner lights, now i just have some hella amber fogs in teh stock location.
i just had to post before the heavy hitters chime in
Shane
Hmmm, i still have those Hella 530s sitting in the garage...
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Old 11-29-2004, 04:45 PM   #7
PARANOID56
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any why havent you use them yet?
Shane
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Old 11-29-2004, 04:51 PM   #8
Rapid_Roo
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Default

Quote:
Originally Posted by PARANOID56
any why havent you use them yet?
Shane
the question is why he hasn't posted his set up yet??? too good for the rest of us huh.

RR
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Old 11-29-2004, 04:56 PM   #9
Psydotek
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Default

Stock:


Slow progression (familiar looking lamps eh?):


Switch to Driving Lamps:


Added afew more lamps:


Current state:


Wiring Central:


Lighting Inventory
Stock headlamps with original bulbs
In Foglamp Wells:
Hella 500 Clear Foglamps loaded with 55w Hella Yellowstar H3 Bulbs (lamps spliced directly into OEM foglamp wiring)
On Upper Light Bar:
Four Hella 500 Driving Lamps with 55w plain bulbs
On Rally Innovations Skidguard (lower light bar):
Two Hella 500 Driving lamps with 55w Hella Yellowstar bulbs

Homemade wiring harness capable of handling up to 100w bulbs for each driving lamp.

The upper bar/bracket cost me about $15 to make ($20 if you count the spraypaint). I used 4 metal bars/straps measuring 3/8"x1"x36" which can found at home depot and 4 sets of nuts/bolts (10mm threaded portion, 17mm head) to hold everything together. The bar attaches to the two top bolts holding the radiator mounting brackts and the two bolts holding the hood latch. It's also attached to the two licence plate screws but only to prevent vibration and bouncing. The licence plate screws bear ZERO weight of the bar & lamps. The majority of the weight is on the two pieces that sit on top of the bumper. They scratch through the paint a little bit but you can't see it when the bar's installed. [my bumper skin has deeper scratches and gouges elsewhere...] Finally the entire bracket was sanded and painted using black duplicolor paint. I touch it up every few months with a shot of black krylon spraypaint.

Other Notes
All 6 driving lamps are hooked to a single paddle switch next to my cruise control switch.


Last edited by Psydotek; 12-08-2005 at 12:43 AM.
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Old 11-29-2004, 04:58 PM   #10
Psydotek
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Default

Quote:
Originally Posted by PARANOID56
any why havent you use them yet?
Shane
I used them for a bit. Look at the pics.
Quote:
Originally Posted by Rapid_Roo
the question is why he hasn't posted his set up yet??? too good for the rest of us huh.

RR
I'm at work here... Gotta keep the Internet usage short and discrete...
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Old 11-29-2004, 05:12 PM   #11
PARANOID56
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Default

ahh, looking good. keep up the lighting fetishes
and nice looking mud flaps too, i just made up a set for my car. (see pics in the mud flap thread)
Shane
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Old 11-29-2004, 05:37 PM   #12
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I've added a link to this thread in the "FAQ and Threads of Note" sticky thread up top so you can always find and refer to it.
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Old 11-29-2004, 05:48 PM   #13
Psydotek
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Schweet.
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Old 11-29-2004, 11:46 PM   #14
Rapid_Roo
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Default

Quote:
Originally Posted by Mulder
I've added a link to this thread in the "FAQ and Threads of Note" sticky thread up top so you can always find and refer to it.

thank you
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Old 11-30-2004, 12:37 PM   #15
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Cibie Tango driving lights in the Morettes, Hella 500 fog lights on Kartboy brackets with the relay wired to the stock switch.

More light than I ever needed even in the most vacant parts of Illinois, Kansas, and Missouri. Pretty easy to wire together, too.

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Old 11-30-2004, 12:54 PM   #16
Rapid_Roo
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Default Here are a few that I found

For the Foresters among us



These were from a Forester that ran the ALCAN (Alaska) Rally.

sorry I only had close ups, I took these at RIM 2004. The nice folks that own the car let me take them so that I could make my own.

Here is another Rally Innovations bar


Last edited by Rapid_Roo; 11-30-2004 at 08:11 PM.
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Old 11-30-2004, 01:00 PM   #17
Psydotek
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Another good solution:

http://www.scoobymods.com/forums/showthread.php?t=1721

Courtesy of wrxinfx:



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Old 11-30-2004, 01:01 PM   #18
Psydotek
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Where's ATX25RS? He's got a nice homemade bar.
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Old 11-30-2004, 01:04 PM   #19
Caliber
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Four Hella 500 100w outer 55w inner.

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Old 11-30-2004, 05:13 PM   #20
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Default Compact 55W Projector Foglights for GD Forester

(1) Purpose: Improve near-field & peripheral vision during inclement weather. Does not need to light up much farther than regular low beams.
(2) Constraints:
* Easy mount --> Projector units are more compact for a given wattage and equivalent lighting effect
* Fog beams that do not cause glare in fog/rain/snow --> sharp cutoff
* As small as possible
(3) Choice: Hella Optilux 1002 (Chrome housing, slightly purple lens). Comes with clear 55W H3 bulbs that emit deep yellow beams. The projector unit has a plate that permits a nice sharp cutoff. Retail price around US$30-60 (depending on where you buy them).
(4) Materials required: Screws, washers, & nuts.
(5) Mounting method: Direct mount on the SG Forester grille by drilling a few holes and trimming the grille to fit the projector profile. The projectors are light enough to not require any lightbar.

(6) Additional picture(s):
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Old 11-30-2004, 05:27 PM   #21
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Default Compact 55W Projector Foglights for Bugeye Impreza


(1) Purpose: Improve near-field & peripheral vision during inclement weather. Does not need to light up much farther than regular low beams.
(2) Constraints:
* Easy mount --> Projector units are more compact for a given wattage and equivalent lighting effect
* Fog beams that do not cause glare in fog/rain/snow --> sharp cutoff
* As small as possible
(3) Choice: Hella Optilux 1802 (Black housing, slightly blue lens). Comes with clear 55W H3 bulbs that emit deep yellow beams. The projector unit has a plate that permits a nice sharp cutoff. Retail price around US$30-60 (depending on where you buy them). Slightly smaller than the Optilux 1002s.
(4) Materials required: Metal brackets, screws, washers, & nuts.
(5) Mounting method: Cut a bracket from any rigid plate to mount the lights to the front clip or the headlight frames. Picture below shows a smaller aux light, but the idea is the same.
Cut an opening on the grille side pieces as shown:

A drum sander tool make things easier:

(6) Additional picture(s):
Installed:

Effect of sharp cutoff viewed head-on from different elevations (-->apparent increase in brightness as viewed from lower elevation):

Effect of sharp cutoff projected onto a wall. One unit was incorrectly rotated in this image:
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Old 11-30-2004, 05:45 PM   #22
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That Forester one is GREAT. Satyra's original design with the little lights in the side pieces was the I was originally going to go with. I even have extra side pieces, but alas I got lazy and I took the easy route and mounted them in the grill.

Thank's for posting Satrya

RR
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Old 11-30-2004, 05:48 PM   #23
Quack
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you guys are making want to put my Hella 4000's (off of my Discovery) on my wagon
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Old 11-30-2004, 05:57 PM   #24
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Quote:
Originally Posted by Rapid_Roo
....
Thank you and you're welcome. How about mounting a pair of the FF75s in front of the grille side pieces instead of replacing the 4000s & 500s?

Call them pairs of aux. foglights, aux passing lights, aux driving lights, and aux spot lights, and you're all set.

On a side note: I find it interesting that most of the posted images of vehicles with added lighting thus far are mostly out of (Sunny) California.

Last edited by satrya; 11-30-2004 at 06:08 PM.
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Old 11-30-2004, 06:00 PM   #25
Rapid_Roo
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Quote:
Originally Posted by satrya
Thank you and you're welcome. How about mounting a pair of the FF75s in front of the grille side pieces instead of replacing the 4000s & 500s?

Call them pairs of aux. foglights, aux passing lights, aux driving lights, and aux spot lights, and you're all set.
I am not replacing the 4000s, I am adding four of the FF75s to the top of the bar

If I ever get any extra money I might get some Hella Projector Fogs and finish that little project and mount them in the side pieces. I still really like the way that looks

RR
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