How To: Rigid Dualy Flush Mounted in rear corner panels.

metzican

Suspension Lift
Location
Lafaytte, la
How To: Rigid Dually Flush Mounted in rear corner panels.

So Today I decided to mount my flush mounted Duallys in my rear bumper step panels. In reality you can mount the flush mounted Duallys, SR series or any other flush mounted lights in this location.

Equapment used:
-1/2 wrench
-Allen wrench
-Sharpie Marker
-Speed Square
-1/4" drill bit
-Drill
-Dremel (sanding tip and Horizontal rotary cutters)

1.) The first thing I had to do was decide where I wanted them mounted. I did not have a huge area to choice from but I decided 1" over from the inside and 2 1/2" up from the bottom. There are no real sharp corners to measure off of but with a good eye ball you should be fine. I used a carpenters speed square for the first line. Then just measured over from the edge for the second.

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2.) Repeat first step on the other side

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3.) Cut out and place provided template onto surface and tape it into desired location from your markings

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4.) With the sharpie outline the desired area to be cut out. Also remember to mark the center of the holes and the outline of them.

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5.) Repeat step three and four on the other side. There is only one template so don't destroy it on the first one.

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6.) Take the gasket and hold it up to all your marks and ensure everything lines up remotely close.

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7.) This is the step where all of you without big enough balls or those who have not had to sober up due to an additive personality. (talk to my physiologist pour yourself a drink and start enjoying it.

8.) Now take your drill and follow your outline. Depending on your skill you might want to leave some extra to clean up with a sanding bit later. This is what I did on the first one. Be careful the dremel likes to follow its own path.

First one
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Second one less sanding was needed
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9.) Take a small drill but and with your fingers twist it to get a starting point in the center of the drill holes.

10.) Take your drill and 1/4" bit, I know the template says 5/16" but this is way to loose of tolerance for me and drill out the four holes.

I forgot to take pictures of it cleaned up.

Slowly sand it open until light fits in. On the Rigid the place where the wire comes out of the light hangs down a little lower this can be a pain in the bum.

11.) Pop the light into place don't forget the gasket. Using the provided hardware reach up behind the bumper. Hope you have very nimble fingers or a short forearm and tighten down all the 4 bolts.

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12.) Repeat on the other side.

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metzican

Suspension Lift
Location
Lafaytte, la
How To: Rigid Dually Flush Electrical.

Now onto the Electrical part. Reminder use glass or eye protection unless your underside is very clean. Dirt loves falling into my eyes.

Equipment
-12gauge wire color of your choice
-wire strippers (knife can work)
-screw driver
-wire crimper (pliers can work)
-Verity of wire terminals
-Solder Iron (if desired)
-Heat shrink tubing
-Drill
-Step Bit (for mounting switches)


Take the stalk harness and cut of the end plugs for the light connection. Also cut off Relay if you desire to use this one. All the wires are either to long aka wires to the battery or to short. Wires to the lights and switch.

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Next take your faverite real of wire. I like using 12 gauge outdoor wire for this part and run it from the battery compartment to the rear. I enjoy the path along the frame rail as you can see I have a few wires already ran along this path. I wish I knew what I was all going to run wires for when I started so I could of just ran 1 large bundle one time.

Wire leaving engine compartment I like using everything on the driver side. Don't worry this is all going to be fixed up to look a lot nicer. I think there are at least 5 bundles of wires I've ran.

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Wire coming out of engine compartment from underneath.

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Wire on top of frame.

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Wire like staying together so keep them together don't forget your zip ties.

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Using the light connectors from the stock hardness, slice these into The wire you ran to the back of your vehicle to supplie power. If your wire is thin walled you might want to use some plastic wire cover you can get at any auto body shop. I used this on the stock wire harness wire its a little thin.

along the back bumper to the passenger side
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Where one wire splits to each light
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Back of Passenger side backup light
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Back of Driver side backup light
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Now onto Running the switch wire.

Take your switch wire and run it through the firewall grommet on the driver side. I take a very small punch and using electrical tape I attach the wire to it. Then use the punch to push my way through the grommet as you can tell I have done this several times and it is yet to tear.
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Then run the wire up the A frame. To do this I remove the oh **** handle by using a small screw driver and prying back the covers for the screws. One of my covers is still attached the other one broke off.
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Once you remove both screws on the oh **** handle. Just grab it and pull. It should come off with little force.
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Then take that little screw drive and pop the cover off of the sun visor screw. Its the side that pivots.
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Remove his screw. Then unbuckle the visor from the right side. Then take the pivot side and slide it towards the back of the vehicle it should move a good 1/4" then fall right onto your lap. On the clip side (right) Just twist the clip 90 degrees and it should fall right out. Neither of these should require much force.
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Now pull the gasket off the door this should not be hard and its easy to put back on. Don' peal it all the way just as far as you need it. Then grab the A frame cover and start pull it off. I start at the top.
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If you keep pulling the cover it will come out all the way.
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Now the cover that runs between the dash and the door below the above mentioned cover should come out real easily.

Now that we have both of those covers off. Open up your glasses holder on the over head thing. Just grab it and from the inside of the glases holder (not the door that holds the glasses) but the inside of the frame and pull down ward. It might be scary but it does pop right out. Now you can undo the two wiring harnesses and walk around with it if you desire. Unless your wiring looks like mine. It will still rest on the central council.

Then using a step bit I drill note very accurate holes as you can tell in the back black plastic just to get the wires through. My switches are to long to just route the wires through the existing holes.
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Then using the same step bit I accurately measure and drill the holes for my switch's.
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Wire up your switch Per manufacture specs. And yes this is how they told me to wire them up. :) I used the same power wire for all switches since it only has to turn on the relays. Used a separate "ground" this is the wire that goes to the relay and supplies power. I also used a separate power wire for the led lights in the switch. So when the switch is on the switch light turns on.

Just getting started with the new wiring. but you can imagine how crazy it looked when I was done.
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Relays:

I bought a grounding strip from home depot and mounting it to the side of the relay box. I ran all wires to the back side so the fuse box cover. This way it can still open. Keep in mind that the back of the bolt might interfere with a relay on the inside of the box. This might be needed or if this is the only lights you will ever run you can just run the ground direct to the battery.

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Grounding strip mounted along with the new relay (10 Relays for 10 devices, Compressor 1, Compressor 2, Switches Power, Forward Light Bar, Right Light Bar, Left Light Bar, Rear Light Bars, LED Fog Lights, Backup Lights) . You can mount these where you want just remember to ground to the battery. Some people choice to mount the relays in the cab under the dash. If this is your desire use the fire wall grommet on either the driver side or passenger side as mentioned above in running the switch wire to get the wires into your cab.

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If you don't know how to wire a Relay here it is (the amps on the diagram are wrong) Rigid recommends for D2s (pair) 15amps, Duallys 10amp. This info should be provided by your light manufacture. When Crimping or Soldering always use heat shrink tubing to help seal it. Don't forget to slide the tubing over the wire before you crimp/solder.

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I ran the wires across the top of the fire wall and zip tied them to the existing wires bundle there. Please remember your zip ties. I just buy the 1000 count bags now. And also your plastic wire cover. It keeps it looking better.

Wires coming out of fire wall grommet and below vehicle.
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Wires started across top of fire wall. The big bundle is stock and this is what I attached them all to.
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Better view, Bad Picture of them coming across. By the way I use small zip ties to seal each small bundle then one big one to attached it to the stock bundle.
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What it looks like as of right now. You can't cover every wire.
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Lessons Learned:
Write down everything in detail. Even if you have a great memory like me. Every color of wire in what bundle where it goes to what it does. I still have to figure out what colors do what on one of my bundles. There the one's for my Gauges. Also Electrical drawing can simplify for anyone who is trying to figure out what you did or how to fix it for you.
 
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metzican

Suspension Lift
Location
Lafaytte, la
Here is my wireing diagram for my vehicle I still have to put in all the colors for the wires and there bundle number.

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I would like to say that the camera does not show how well these lights work.

Back up Duallys only.
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This is with the top rear lights
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metzican

Suspension Lift
Location
Lafaytte, la
Very sweet man! Good idea.!

Sent from my LG-E970 using Tapatalk 2

You finally get to see where all those LED Light Bars are being mounted. By the way If anyone wants rigid lights talk to Offroadperformanceparts.com

Thanks everyone for the compliments. I do a lot of stuff to my vehicle but normally I forget to take pictures and whats a how to without them. And after shots are only so good.
 

metzican

Suspension Lift
Location
Lafaytte, la
Everything is updated as far as the how to on the wiring. Need to update the wire diagram and do action shots. I tested all the lights and they work. All the switch lights work too but one, the forward one. So I will have to take a look at that. If anyone has questions please ask. By the way if you want to know how long it took. To bad I instaled fog lights while doing this too. and also revamped a lot of the wiring I had to make it look better.
 
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