Custom LED Foglight pod project

[Stewi]

So I started to make a set of custom led pod brackets to use as fog lights. I see that one common bracket everyone uses but I don't like the look of the pods sitting a few inches behind the bumper cut out the way the stock fog light is setup. I decided to run an OPT7 18w 6 LED pod. My goal for these is to function like traditional fogs and face outward on an angle to illuminate the edges of the road where the headlight beams don't shine. I also wanted them to sit as close to flush as possible in the bumper cutout.

I started by making cardboard templates of the bumper opening and the LED pod, then transferring it over to a piece of 1/8" aluminum and cutting it out on the band saw. I could have cut the pod opening with a dremel but using the saw was easier and it took less than 10 minutes to weld it back together and grind the welds smooth.





Made it bolt up just like the stock fog light. I was happily surprised to find out the OPT7 pods came with 9006 connectors on them, so they were plug and play.







This is the spot beam pattern. I haven't aimed it yet, I want to bring it a little more to the right and a little more down. I'm going to be leveling on Bilsteins later this week and possibly a 3" body lift in the near future.



Tomorrow I'll finish welding up the other bracket and decide how to finish them. I'm thinking of spraying them with bedliner.

 

[Paluby]

That looks sweet man. Only thing I would do for mine would paint the frame. But definitely intriguing. Kudos.

 

[BlownGP]

Nice work..

Do you plan on keeping them to side or bringing towards the front?

 

[Stewi]

I want them to the side but not as drastic as in that pic. I'm thinking maybe aimed about 2 feet more to the right and down a bit more to compensate for when I level it.

 

[Limeybastard]

I love vision, and you have it.

 

[Stewi]

I love vision, and you have it.

Thanks man. I'm an import car guy, Mitsubishi Galants and Evo's. I've learned from modding the galant which has little aftermarket support, if you want something a certain type of way, just make it yourself from scratch instead of modifying a part that you'll never be happy with.

 

[ufokillerz]

great project, only thing is why spot beam? doesn't seem like it would function as the fog light normally would? Have you considered the Rigid Led Fogs?

 

[Stewi]

great project, only thing is why spot beam? doesn't seem like it would function as the fog light normally would? Have you considered the Rigid Led Fogs?

I personally can't afford the Rigid LEDs. I wanted to try out the spot beams because I figured the beam is more focused, it would let me direct the light exactly where I wanted it. I'm not totally opposed to flood beams and I may in fact try a set and see the difference. I have a 42" curved light bar with floods on the ends that I haven't installed yet. I want to wait until the light bar is installed and my HID projectors before I make the decision.

 

[Limeybastard]

Thanks man. I'm an import car guy, Mitsubishi Galants and Evo's. I've learned from modding the galant which has little aftermarket support, if you want something a certain type of way, just make it yourself from scratch instead of modifying a part that you'll never be happy with.

Same here, most past vehicles were either bavarian or oriental.

 

[JGBimle]

This is a pretty cool idea I really like it. I've been thinking about trying to make some brackets to mount a 7" bar vertically in there

 

[Stewi]

This is a pretty cool idea I really like it. I've been thinking about trying to make some brackets to mount a 7" bar vertically in there

That's what I originally wanted to do. I wanted two vertical bars side by side but the cutout isn't tall enough to fit the 7" bar and be flush. If I did it, it would be recessed the way the stock lights are. I may try a different style at some point. The hardest part was getting the bracket to sit exactly how I wanted and use the factory bolt holes. I'm gonna build a jig off the bracket so that I can easily make more. The first one I made took me about 4 hours or so, the 2nd one took me about an hour and 15 mins since I had all the measurements already.

 

[Rzrman328]

Original.

I like your thinking.

 

[streetmechanix]

I 100% dig the look, I wanted to build one as well... but then I saw the "altered offroad" kit on eBay... it was a little over 200 with 4x6led pods... I did 2xSpots and 2xFloods... 1 per side... doesn't look as good as yours when their off

 

[BlownGP]

I 100% dig the look, I wanted to build one as well... but then I saw the "altered offroad" kit on eBay... it was a little over 200 with 4x6led pods... I did 2xSpots and 2xFloods... 1 per side... doesn't look as good as yours when their off

I planned on doing the pods on mine, but they just look really weird during the day like they don't belong there.

If there a bracket that set them farther out and covered them up around the side to make look like their built in. I would do it.

 

[streetmechanix]

there is room to play, I bought my kit after hitting road debris that cracked the factory foglight... the bracket behind the bumper is cracked also, I just got the replacement in so I will be making some changes but I do believe there is a possibility to mount them further forward and fill the gaps

 

[michaelrc51]

Thanks man. I'm an import car guy, Mitsubishi Galants and Evo's. I've learned from modding the galant which has little aftermarket support, if you want something a certain type of way, just make it yourself from scratch instead of modifying a part that you'll never be happy with.

Nice work!

You on Evom too?

 

[Stewi]

Nice work!

You on Evom too?

Yeah my username over there is VTEC Killer

I don't go there often since I parted out most of my race car.

 

[JGBimle]

That's what I originally wanted to do. I wanted two vertical bars side by side but the cutout isn't tall enough to fit the 7" bar and be flush. If I did it, it would be recessed the way the stock lights are. I may try a different style at some point. The hardest part was getting the bracket to sit exactly how I wanted and use the factory bolt holes. I'm gonna build a jig off the bracket so that I can easily make more. The first one I made took me about 4 hours or so, the 2nd one took me about an hour and 15 mins since I had all the measurements already.

After you get everything figured out on these brackets I think I'd be interested in a set if you'd be willing to make some. Been trying to figure out something to do with my fogs. Right now I just have cheap LED bulbs to match my HIDs. I had been wanting to pull apart my fogs and mount an LED cube inside them but they're permasealed and I don't think I feel like trying to mess with them. I have Rigid Duallies in place of my high beams inside my headlights so I'd love something to match for fog lights like this.

 

[Stewi]

I'll keep you in mind. I'll have some free time later this month to maybe make a few sets.

 

[Stewi]

So if finally stopped raining so that I could install the other side and mess around a little with aiming them. I've determined the only real way to aim them is shim the mounting points using washers. I know it's a bit primitive but it is effective and gives the best aesthetic results in allowing the pod to fit snug into the bezel. I got the beams over about 18-20" toward the center, I still wanna go over more but I ran out of washers that size : ( Tomorrow I'll aim them again and then remove them so I can spray the bezels. Anyhow, I snapped a few pics and here they are....