M809 recessed IR / Driving light mount

[Brutacus]

One thing I have noticed is that just about every one likes the IR driving lights, despite there is no real use for them. At least for me. LOL If a clear lens/non filtered lens can be had, then it can be used as an auxiliary light. The other problem is where to mount them. I have seen some creative ways and methods, some clean and nice, others... zip ties and duct tape. I have been going over my parts collection and have found a way to mount one under the passengers side headlight, in a similar way to the black out light on the drivers side. I don't know if this has been done before, but I will make it happen somehow.

Starting with an IR light, and a blackout light bracket. I had to grab and pull on the bracket to make it wide enough to fit the IR light in it. It was a little tight a first, now it has some room.

I have a N.O.S. headlight panel, (mine is bent and warped, hit a tree, I think)



Here is where I want to mount the light from the inside, I'm using a 6" Bi-metal hole saw I found for $14


Here is what I want the finished outcome to look like, more or less.



Just a side view for reference.


The new head light bucket, just to make a better perspective of it. Just incase anyone is wondering, the head light bucket came with the panel.




I'll have to make the rounded cut outs for the 4 ears on the IR light. When I do that, I'll center the light and drill the holes for mounting my bracket.


I have made some measurements, and this location will leave the IR light clear of the grill. Meaning it will not have any obstruction in front of it. I will have to make an alteration to the fender to clearance the IR light. I figure I can use 4" hole saw to do so, then rivet in a metal dish is the hole. I haven't gotten that far along yet, but that's what I'm thinking of right now. I'm also thinking of painting the front/inside of the panel and bucket flat black (911 black) as apposed to leaving it green. The exterior would still be green.

 

[Brutacus]

Here is my proof of concept, I'm going to smooth and round out the notches for the ears on the IR light. After that is done, I'll use an epoxy primer on it and go from there.



You can see from the back it will clear the head light bucket.


These next two pictures shows the need to modify the fender to clear the IR light. If you look at the angle of the panel that mounts to the fender, and how the IR light protrudes past it. I'm now thinking of an oval shaped hole cut into the fender to clearance the IR light. I don't think it would be as big as I was thinking it would need to be.

 

[Brutacus]

I have finally gotten to mount my IR driving light. I had to cut a bigger than I liked hole in the fender to clear the light bucket. Here are some pics of the project so far. I still have to hit it with some more paint, and wire it up. I was thinking about using an OFF-ON-ON switch for the low and high beam for the light.





I'm pleased with how it is turning out, but I will have to adjust the lights too. They seem crooked to me. I did add a head light grill from Those military guys. I have one for the other side too, I just haven't gotten around to working on that side yet.




I want to paint the other head light panel flat black also, but that's for another day.

 

[Elijah95]

Clean work


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