Good morning all. I have a small project and a larger project to highlight. But first, I would like to thank all the forum members who post their projects, provide pictures, share their processes, and perhaps even a mistake or two. I reached out to a few with questions about their builds and recommendations. Everyone was great, thank you!
Small project - Installation of a Streamlight cradle to store and recharge a Streamlight LED flashlight. A simple tap to a 5-amp fuse, ground it, and it's good to go.
Larger project - Installation of a BajaDesign OnX6+ 20-inch light bar and a pair of BajaDesign S2 Sport auxiliary lights. It was a slow and methodical installation; I did research on the INEOS forum, located the 25-amp and 10-amp wiring harnesses under the bonnet, stripped the wax/heat shrink on the 25 and 10-amp harnesses (which was a pain, patience is the key), extended both the 25 and 10-amp harnesses with female Delphi waterproof connectors, removed the skid plate, measured once, twice, three times, drilled the front bumper (more on this later), installed the light, removed the driver's side front light cover, ran the Baja Design wiring harnesses through the grill to the driver's side light to the engine bay, connected, tested, zip-tied wiring harnesses to existing ones in the engine bay area, and enjoyed.
A few lessons learned: 1) The BajaDesign OnX6+ LED light bar is an absolute beast - it emits a lot of light. I have a pair of BajaDesign LP6s on my Tacoma, and the OnX6+ is substantially more powerful. I debated between the 30-inch and the 20-inch, and I'm very pleased with my decision on the 20-inch and highly recommend it. I believe it is the right size, and it made the installation easier as well, 2) One item that I did not anticipate was the length of the hitch steel from the front-mounted tow hitch on my IG Trailmaster. The hitch steel runs the entire length of the front, middle part of the bumper. This was discovered after I removed the skid plate. Two issues: the mounting bracket of the OnX6+ was outward (mounting bolts on the outside of the LED light) and would be impossible to drill as the hitch steel came to an angle to mount to the IG. The solution was to place the mounting bracket inward, so the mounting bolt is under the LED light bar and not to the side, 3) Measure once, twice, three times, mark, drill. What I was unable to measure and see exactly is where the mark was on the hitch steel under the bumper plate. I measured and drilled too close to the front of the hitch steel (uhhhhh). The solution was to move the mounting holes back about an inch and place a plug in the 'whoops' holes (all bare steel was primed and painted). 4) There is a space between the bumper plate steel and the hitch steel. When you tighten the mounting bolts, the bumper steel bends down to close the gap between the two. The solution was to use stainless steel washers to fill the gap.
I tested the lights this morning on the way to work. The OnX6+ is very powerful. I am very impressed with this light. The S2 Sport auxiliary lights are a perfect complement to the IG front headlights; they provide additional light, but not too much where it blinds oncoming traffic for several moments.
A list of a few additional parts required: 1) Baja Design wiring harness part 640094 (to wire to the OEM 25-amp auxiliary switch) OnX6+, 2) Baja Design wiring harness part 613606 S2 Sport splitter (to bring two lights to one harness) and Baja Design 640093 (to wire to the OEM 10-amp auxiliary switch) S2 Sport, 3) male and female Delphi waterproof connectors, 4) 3/8-16 2.5-inch stainless steel hex cap screws (two), washers, nylon locking nuts, 3/8-inch x 1 zinc post (two), and 5) an extended L bracket to mount S2 Sport on the side of the LED light bar (Amazon).
box on the drive. Everything was driven up to those so I could get visitors cars on the drive as well.
