Auxiliary Lights in the Grill - High Power LED light upgrade without any cutting (now available on the Forum Store)

[BenTN]

Update on the forum community effort to develop even more options for mounting LEDs in the stock grill location:

We now have 5 different light sets in hand or on the way for testing.
- Diode Dynamics SS3 sent by @anand (in hand)
- KC Hilites Flex Era 4 sent by @Stu_Barnes (due later this week)
- Clearwater Super Sevina, courtesy of Glenn at Clearwater Lights (due this Fri)
- Clearwater Dixi, courtesy of Glenn at Clearwater Lights (due this Fri) [unlikely to fit in stock bezel]
- Exzeit LML-5064B (the first ones I installed)

I plan to start test fitting again late this week. I will send a report on progress when there is something interesting to show.

 

[grenadierguy]

Update on the forum community effort to develop even more options for mounting LEDs in the stock grill location:

We now have 5 different light sets in hand or on the way for testing.
- Diode Dynamics SS3 sent by @anand (in hand)
- KC Hilites Flex Era 4 sent by @Stu_Barnes (due later this week)
- Clearwater Super Sevina, courtesy of Glenn at Clearwater Lights (due this Fri)
- Clearwater Dixi, courtesy of Glenn at Clearwater Lights (due this Fri) [unlikely to fit in stock bezel]
- Exzeit LML-5064B (the first ones I installed)

I plan to start test fitting again late this week. I will send a report on progress when there is something interesting to show.

Amazing effort Ben and team!

 

[[ Adam ]]

Great stuff for sure!

 

[CQ1]

Since I originally posted about this effort (Auxiliary light replacement with higher power LEDs) a few weeks ago, some new relevant products have been announced or have come to my attention. I thought I would collect the products I know about in one post so that people can see what is on the market now. Most of these were found by forum members and some have already been posted here in this thread. If you know of something that I have missed, please post it here.

Early entry in the market, a pair of small light bars (88-104W total) from Lazer Lamps (Triple-R) that requires cutting of the stock grill:
View attachment 7852380

VisionX lights (~100W total) with a bracket design similar to the ones that I made, does not seem to require cutting:
View attachment 7852381

Agile Off-Road integration of Baja Designs XL-R Pro lights "coming soon". Not many details have been announced about this kit but I am guessing there is no cutting required.
View attachment 7852382

ShadowMarq integration of KC Hilites Flex Era 4's said to be available "next month" per a post on Instagram. Appears to include a custom molded bezel. I assume no cutting required.
View attachment 7852383

Owl Outdoor (Owl Vans) has a vehicle with with Baja Designs LP4's installed. I don't have any info about this as a kit.
View attachment 7852385

And just for comparison, this fine integration is my amazon special. 160W total and retains the classic round look. No cutting.
View attachment 7852384

What did I miss?

Lazer Lamp 7" Sentinels Elite, a guy named Gregor McArthur on Facebook fitted them. No info on the mount... but it looks nice.

 

[DaveB]

Lazer Lamp 7" Sentinels Elite, a guy named Gregor McArthur on Facebook fitted them. No info on the mount... but it looks nice.

Exactly what I want

 

[BenTN]

Lazer Lamp 7" Sentinels Elite, a guy named Gregor McArthur on Facebook fitted them. No info on the mount... but it looks nice.

This is a great find. Early on I spent a lot of time staring at the empty grill after removing the stock Aux lights... imagining what could be made to fill in the gaps around a large light installed like this. Cool to see someone did it.

The trick here is that the stock round bezels hide some attachment features and other un-finished details in the molded grill. Leaving that area exposed is possible, but it's not pretty. Also, the round bezel is functional in that it retains and protects the ends of the chrome strips that are laid into the horizontal grill bars. This is not obvious, but I discovered that the chrome strips are fairly delicate and can be pulled out easily if the ends are exposed. I broke one just investigating their construction.

I was thinking about 3d-printing some trim pieces that would fill in the grill gaps and also retain the chrome strips, which appears to be what was done here. Long-term, this solution did not fit my goal of enabling people to swap these lights easily, since 8 different trim pieces are required.

I'd love to hear from the designer of this mod. Perhaps they would be willing to share the 3D print files here on the forum. It seems to be a nice execution of a larger light install.

 

[Jörk]

Hello together
I am also very interested for better lights in the grill. In Germany we need to have a e number means registration for Europe.
Vision X has it and you can take different cups on the lights for fog, snow and so on. But the price! Around 1300€ bracket included isfor me to expensive. Without the bracket for Ineos the price in Europe is around 800€. This is acceptable. But the bracket?

 

[NixGrenadier2023]

This is a great find. Early on I spent a lot of time staring at the empty grill after removing the stock Aux lights... imagining what could be made to fill in the gaps around a large light installed like this. Cool to see someone did it.

The trick here is that the stock round bezels hide some attachment features and other un-finished details in the molded grill. Leaving that area exposed is possible, but it's not pretty. Also, the round bezel is functional in that it retains and protects the ends of the chrome strips that are laid into the horizontal grill bars. This is not obvious, but I discovered that the chrome strips are fairly delicate and can be pulled out easily if the ends are exposed. I broke one just investigating their construction.

I was thinking about 3d-printing some trim pieces that would fill in the grill gaps and also retain the chrome strips, which appears to be what was done here. Long-term, this solution did not fit my goal of enabling people to swap these lights easily, since 8 different trim pieces are required.

I'd love to hear from the designer of this mod. Perhaps they would be willing to share the 3D print files here on the forum. It seems to be a nice execution of a larger light install.

Hi BenTN, so I've been looking at my grill also... But haven't removed it. I hope I can NOT remove the complete grill, and simply remove the bezels and aux lights. Is this possible? Feeling behind the bezel, it looks like there are 4 screws into the plastic... Although difficult to access, it might be possible to unscrew them and remove the lights. Anyone have any comments?

 

[BenTN]

Hi BenTN, so I've been looking at my grill also... But haven't removed it. I hope I can NOT remove the complete grill, and simply remove the bezels and aux lights. Is this possible? Feeling behind the bezel, it looks like there are 4 screws into the plastic... Although difficult to access, it might be possible to unscrew them and remove the lights. Anyone have any comments?

It is not practical to remove the aux lights without almost removing the grill. The bezels attach with blind screws from the rear and removing them requires the grill to be loosened and tilted forward. Tilting is preferred, since full removal requires partial disassembly of the bumper.

The tilting procedure is fairly well documented at the link below. I've done it a few times now and can get through the entire process in about 10 mins. Allow 30min the first time. You will need plastic panel removal tools for the hood (bonnet) seal clips and to pop off the fender (wing) fronts. Take your time and make little piles of the fasteners, since there are a number of different sizes and lengths. Mixing them up can cause issues during re-assembly.

View: https://www.youtube.com/watch?v=yb-1V2pVd3Y

 

[NixGrenadier2023]

It is not practical to remove the aux lights without almost removing the grill. The bezels attach with blind screws from the rear and removing them requires the grill to be loosened and tilted forward. Tilting is preferred, since full removal requires partial disassembly of the bumper.

The tilting procedure is fairly well documented at the link below. I've done it a few times now and can get through the entire process in about 10 mins. Allow 30min the first time. You will need plastic panel removal tools for the hood (bonnet) seal clips and to pop off the fender (wing) fronts. Take your time and make little piles of the fasteners, since there are a number of different sizes and lengths. Mixing them up can cause issues during re-assembly.

View: https://www.youtube.com/watch?v=yb-1V2pVd3Y

Thanks for the reply. I had seen the Lazer video a while back, but was hoping that the reason they did a complete removal was because they had to chop the grill anyway. I had pretty much come to the conclusion that the aux lights can't be removed without removing the grill, just not how I would have designed the Grenadier if Ineos had asked for my input!

 

[BenTN]

Lots of progress since my last update a couple weeks ago!

I received all of the sample lights for test fitting in the grill of my Grenadier. In addition, I (well OK actually a co-worker) scanned some of the LED podlights, and we also scanned the aux light bucket in the vehicle grill. The grill had to be sprayed with white powder to make the dull black plastic show up properly for the laser scanner. Other podlights and the round bezel were more easily measured by hand.





This bracket design task could be tackled by making cardboard mockups and iterating prototypes until it all fits. However I do a lot of product design work in CAD so for me it was most convenient to get everything scanned/measured and modeled and assembled together on the computer, then do bracket design in this environment. It's a good strategy when you have complex shapes (like cast pod light housings and molded grill buckets) interacting in tight spaces and you can't see clearly how everything is fitting together. Image below shows a cross-section of the CAD model with bezel (partial) to the left and the scanned grill bucket to the right. You can see that the podlight housing protrudes through the mount bracket in order to sink the light into the bezel as deeply as possible.



This photo shows all of the lights with their prototype (3D-printed) brackets. Forgive the yellow color...final brackets will be black.



Top to bottom they are:
1- Exzeit
2- KC Hilites
3- Diode Dynamics
4- Clearwater Super Sevina
5- Clearwater Dixi

My next post will break each of these down in some detail.

 

[BenTN]

This post contains a breakdown of the 5 lights I worked with, with pros & cons (as I see it) to help clarify the differences between options.

1) Exzeit LML-5064B (160W total)
US$80/pair
Pros: cost/availability, classic round shape fits grill bezel, high output
Cons: off-brand manufacturer (quality unknown), single lens/beam selection





This is the option that has been tested in actual use with metal brackets on my car. I am thrilled with the result given the modest investment. I think this simple round shape looks great in the grill.

Light pods are available on Amazon: https://www.amazon.com/gp/product/B083NMF64M/?tag=globalgrena0b-20

Verdict: I plan to order a few sets of these brackets to distribute to early adopters. Will order more if interest is there. Should be sending them out by mid-May.


2) KC Hilites Flex Era 4 (160W total)
US$650/pair
Pros: established manufacturer, modern style, high output, changeable lenses
Cons: squared shape does not match round vehicle bezel, protrudes forward of bezel due to depth

This is a high-quality light and a great fit. Fit-up sample lights were provided by Mr. @Stu_Barnes himself.

FLEX ERA® 4 - 2-Light Master LED Light Pod Kit

Standing as the powerhouse big brother of the KC FLEX ERA family, the KC FLEX ERA® 4 LED Light Pods doesn't shy away from challenges. With an IP68 rating, amber backlighting, high-intensity LEDs, and customizable beam patterns, bezels, and covers, it's primed and ready to allow you to Adventure...

www.kchilites.com

Verdict: Stu plans to order a few sets of these brackets to distribute to early adopters. We will order more if interest is there. We should be sending them out by mid-May.


3) Diode Dynamics SS3 (80W total)
US$500/pair (lower also available)
Pros: established manufacturer, modern style, very compact, sits back within round bezel
Cons: not very powerful, does not fill bezel, wire exit location results in sharp bend at bucket

Search results for: 'catalog product view id 17507'

Automotive LED lighting for cars and trucks, including headlight, fog light, turn signal, backup, tail, interior, halos, demon eyes, boards, strips, and more!

www.diodedynamics.com

Verdict: Not yet sure if there is sufficient interest in this light to justify ordering metal brackets for further testing.


4) Clearwater Lights Super Sevina (140W total)
US$1269/pair
Pros: classic round shape matches bezel, high output
Cons: expensive, fitment is still in development, does not quite fill round bezel, will require a hole drilled in grill bucket for wire clearance

I didn't get any good pics of test fitting this one on the vehicle, so here is CAD and a gif to look at. This light's basic style is the same as the Dixi, below. But this one can be recessed back into the bezel better.

Clearwater is enthusiastic about supporting this community with a high-end solution. The sample light I received from them for mockup was not functional and did not include a couple features needed for final evaluation. I will try to stay on them to keep this moving forward.

Super Sevina Universal LED Light Kit

World’s most advanced LED auxiliary light – brighter than any high beam, fully dimmable, flood beam pattern, and multiple mounting options. 70 watts with 10,000+ lumens and only 6-amp power draw at max output per light. 4.7” diameter housing – great for motorcycle or vehicle Dimmable using...

www.clearwaterlights.com

Verdict: I think this is a great future option. I will continue to work with Clearwater and any early adopters that want to help us proceed.


5) Clearwater Lights Dixi (200W total)
US$1369/pair
Pros: this thing is an absolute unit, VERY powerful, classic round shape matches bezel perfectly
Cons: expensive, fitment is still in development, will require a hole drilled in grill bucket for wire clearance

NOTE: photos below show empty podlight shell without LEDs or lenses

Clearwater is enthusiastic about supporting this community with an ultra high-end solution using this large light. The sample unit I received from them for mockup was not functional and did not include all features needed for evaluation. I plan to keep this moving forward because I might install this light on my own vehicle when it is all sorted.

Dixi Universal Off-Road light kit

Dixi incorporates two different beam patterns that can be used. There are three LEDs in the center and seven LEDs around the outside. The outside group is basically a Sevina pin spotlight using seven 8 degree optics. The center three LEDs use a Darla optic which provides a driving beam. But, the...

www.clearwaterlights.com

Verdict: I think the Dixi is a great future option. I will continue to work with Clearwater and any early adopters that want to help us proceed.


A special thank you to @Stu_Barnes , @anand , @IG_in_AZ , @BoiseIdaho , @DaBull , @Tom109 , @nmoeder , @stickshifter , and others for their help behind the scenes.

The next step is to decide how many metal bracket kits we order. This will be influenced by the community response here on the forum. I will help get the components on order, and Stu will provide worldwide distribution via the forum store (just like we did with the reverse camera light shrouds). My wild guess is that the bracket kits will be sold for ~$150 with hardware. You order the lights separately yourself.

So let Stu know with your comments; which option would you want to see available thru the forum store?

 

[crashnburn]

Very well done!
And to those who supported behind the scenes.
Much effort done for the IG community.

Is there a certain bracket which could possibly be used for more than one type of light?

 

[Robert T]

Amazing work @BenTN. I would go for the Exheit LML-5064B bracket. Thanks

 

[dreamalaska]

Can @Stu_Barnes create a poll for each? I cant figure out how to do that

 

[BenTN]

Is there a certain bracket which could possibly be used for more than one type of light?

At this point I don't see a way to make a truly universal bracket.

However, there are some 3in to 4in diameter lights that come with a mount bracket that could be pivoted towards the grill such that they could be "wall" mounted. We could then make a completely flat mount plate that attaches inside the grill aux light buckets. This would allow someone to drill their own holes and mount a pod light such as this. If people are interested (and find some candidate lights) I could explore that.

 

[grnamin]

I like the KC Hilites Flex Era 4.

 

[Cheshire cat]

This post contains a breakdown of the 5 lights I worked with, with pros & cons (as I see it) to help clarify the differences between options.

1) Exzeit LML-5064B (160W total)
US$80/pair
Pros: cost/availability, classic round shape fits grill bezel, high output
Cons: off-brand manufacturer (quality unknown), single lens/beam selection

View attachment 7854129

View attachment 7854130

This is the option that has been tested in actual use with metal brackets on my car. I am thrilled with the result given the modest investment. I think this simple round shape looks great in the grill.

Light pods are available on Amazon: https://www.amazon.com/gp/product/B083NMF64M/?tag=globalgrena0b-20

Verdict: I plan to order a few sets of these brackets to distribute to early adopters. Will order more if interest is there. Should be sending them out by mid-May.


2) KC Hilites Flex Era 4 (160W total)
US$650/pair
Pros: established manufacturer, modern style, high output, changeable lenses
Cons: squared shape does not match round vehicle bezel, protrudes forward of bezel due to depth

View attachment 7854132 View attachment 7854133

View attachment 7854131 View attachment 7854138

This is a high-quality light and a great fit. Fit-up sample lights were provided by Mr. @Stu_Barnes himself.

FLEX ERA® 4 - 2-Light Master LED Light Pod Kit

Standing as the powerhouse big brother of the KC FLEX ERA family, the KC FLEX ERA® 4 LED Light Pods doesn't shy away from challenges. With an IP68 rating, amber backlighting, high-intensity LEDs, and customizable beam patterns, bezels, and covers, it's primed and ready to allow you to Adventure...

www.kchilites.com

Verdict: Stu plans to order a few sets of these brackets to distribute to early adopters. We will order more if interest is there. We should be sending them out by mid-May.


3) Diode Dynamics SS3 (80W total)
US$500/pair (lower also available)
Pros: established manufacturer, modern style, very compact, sits back within round bezel
Cons: not very powerful, does not fill bezel, wire exit location results in sharp bend at bucket

View attachment 7854135 View attachment 7854136

View attachment 7854137

Search results for: 'catalog product view id 17507'

Automotive LED lighting for cars and trucks, including headlight, fog light, turn signal, backup, tail, interior, halos, demon eyes, boards, strips, and more!

www.diodedynamics.com

Verdict: Not yet sure if there is sufficient interest in this light to justify ordering metal brackets for further testing.


4) Clearwater Lights Super Sevina (140W total)
US$1269/pair
Pros: classic round shape matches bezel, high output
Cons: expensive, fitment is still in development, does not quite fill round bezel, will require a hole drilled in grill bucket for wire clearance

I didn't get any good pics of test fitting this one on the vehicle, so here is CAD and a gif to look at. This light's basic style is the same as the Dixi, below. But this one can be recessed back into the bezel better.

View attachment 7854160 View attachment 7854139

Clearwater is enthusiastic about supporting this community with a high-end solution. The sample light I received from them for mockup was not functional and did not include a couple features needed for final evaluation. I will try to stay on them to keep this moving forward.

Super Sevina Universal LED Light Kit

World’s most advanced LED auxiliary light – brighter than any high beam, fully dimmable, flood beam pattern, and multiple mounting options. 70 watts with 10,000+ lumens and only 6-amp power draw at max output per light. 4.7” diameter housing – great for motorcycle or vehicle Dimmable using...

www.clearwaterlights.com

Verdict: I think this is a great future option. I will continue to work with Clearwater and any early adopters that want to help us proceed.


5) Clearwater Lights Dixi (200W total)
US$1369/pair
Pros: this thing is an absolute unit, VERY powerful, classic round shape matches bezel perfectly
Cons: expensive, fitment is still in development, will require a hole drilled in grill bucket for wire clearance

NOTE: photos below show empty podlight shell without LEDs or lenses

View attachment 7854140 View attachment 7854141
View attachment 7854142 View attachment 7854143

Clearwater is enthusiastic about supporting this community with an ultra high-end solution using this large light. The sample unit I received from them for mockup was not functional and did not include all features needed for evaluation. I plan to keep this moving forward because I might install this light on my own vehicle when it is all sorted.

Dixi Universal Off-Road light kit

Dixi incorporates two different beam patterns that can be used. There are three LEDs in the center and seven LEDs around the outside. The outside group is basically a Sevina pin spotlight using seven 8 degree optics. The center three LEDs use a Darla optic which provides a driving beam. But, the...

www.clearwaterlights.com

Verdict: I think the Dixi is a great future option. I will continue to work with Clearwater and any early adopters that want to help us proceed.


A special thank you to @Stu_Barnes , @anand , @IG_in_AZ , @BoiseIdaho , @DaBull , @Tom109 , @nmoeder , @stickshifter , and others for their help behind the scenes.

The next step is to decide how many metal bracket kits we order. This will be influenced by the community response here on the forum. I will help get the components on order, and Stu will provide worldwide distribution via the forum store (just like we did with the reverse camera light shrouds). My wild guess is that the bracket kits will be sold for ~$150 with hardware. You order the lights separately yourself.

So let Stu know with your comments; which option would you want to see available thru the forum store?

Fantastic work and a big thank you to you. For me, the Exzeit LML-5064B are my favourite.

 

[crashnburn]

Exzeit for me too.

Thanks!

 

[TelRidan]

I am definitely interested in the Clearwater Lights Dixi version and will be happy to put up some pre-order money if that helps the bracket development.