Mirror-mounted Baja S2 DIY

MESO · Jun 21, 2019

sagexp said: ↑

Didn't take progress pics since robmpii pretty much had all the bases covered.

Returned the S2 sports and decided to go with the S2 Pros. Trying out the sports at home and wasn't convinced they'd give the light output I was looking for. Besides, can't recall ever being in an off road situation where I thought to myself "ya know, I could really use a little less light here". So the Pros in wide cornering it was.

Took the factory mirrors off the truck and put on my replacement mirrors and factory mirror caps. Wasn't in a hurry (obviously since I've been tinkering with this for going on two months now on and off) and worked on this when I had some time to kill over four or five weekends, including painting, wet sanding, wiring, etc. Used the replacement mirror caps instead of factory caps, so I did have to paint the caps I cut up. Even if you were to use the factory mirror caps, you're still painting them otherwise the white plastic underneath will show when you cut into them.

Thanks to robmpii's pics, I knew just where the cutouts in the mirror caps needed to be to fit the lights within the housing, but with the twist of getting the lights more level versus following the bottom mirror cap contour line as rob did. Struggled with that decision for a while, but mocked it up with a couple S2 faceplates and double stick tape on my oem mirrors, and decided "what the hell, let's try them level."

Situated the light face plates on the caps, scribed out the cuts, and then outlined with masking tape. Got a rough cut out in the caps (about 1/8" shy of finished size), and then worked slow and patiently with a small battery operated Dremel on low to lowest speed and some small hand files. Using the S2 faceplate (grind, try to fit the faceplate in the hole, grind and file some more, repeat), finished up the fit until the lights just fit the opening, with just a hair of a gap or reveal around the lights so I wouldn't be possibly damaging or chipping paint pulling covers on and off to make final adjustments once installed on the truck.

Finished the cutouts, fitting, and painting of the mirror caps a few weeks ago. Was really happy with the fit and overall outcome. Unfortunately while wet sanding I slightly exposed an area of basecoat on an edge. Hardly noticeable, but being anal about such things and knowing this would ruin my enjoyment of the little project, had to start over, re-spray, clear coat, wet sand and polish the caps. My first attempt at a automotive finish with rattle cans, or really any automotive painting at all, but got them to come out right on the 2nd attempt.

Let the caps dry for two weeks, put them back on the mirrors, and got the mirrors installed and wired up today. Will wax them in a month or so. Very pleased overall.

The paint match for quicksand from automotivetouchup, well, not perfect. But it's pretty close, and I'm not re-spraying them again. I have some experience in finishing (fine woodworking), but I'm not a painter and this was my first attempt at a rattle can automotive finish, so after two attempts (1st one I wet sanded through the clear), I'm satisfied with the finish on this one, if not the color match. It is what it is. I'm more concerned with the fit and finish than I am the fact the paint is not quite a spot on match.

Picked up a can of the Rustoleum Gloss Khaki, and that was close as well, but a couple shades off on the lighter side. Seemed more "off" than the automotivetouchup was. Plus, that paint (Rustoleum) seems to take forever to dry to touch and off-gas, so I wasn't going to risk it. I may try that paint on the bumper caps though.

Not exactly an "easy" bolt on type project, but fairly easily doable if you have time, are not prone to rush things, like to tinker, and have patience. Very much worth the expense and effort (at least to me) to get a couple of lights on to light up the sides without resorting to a-pillar pods. Plus, once I saw robmpii's pics, I knew I HAD to have those!

Lessons learned;

1. Use enough coats of clear to be able to wet sand! I'm a newbie to rattle can and base coat / clear coat painting, so I wasn't aware of just how many decent coats it would take to give enough depth for wet sanding and finishing.

2. Remove BD S2 face plates when installing and removing modified mirror housing covers. The faceplate is slightly larger than the light body, and has a fairly sharp edge on the back of the plate which can mar or chip paint on edge of cutout. I found this out after my 1st paint attempt. But because I had to re-paint anyway due to sanding through the clear, no lasting harm done.

3. Get the light aim and orientation of the lights in the housing right before removing covers for last time for painting. This will help prevent accidental damage to paint from pulling and reinstalling cover multiple times trying to adjust the light aim, and also adjusting the light fit within the covers.

4. Once painted, wet sanded and polished, allow paint enough time to cure before messing with it again. I gave the covers 2 full weeks to cure out and harden before they even went anywhere near the housings again so I wasn't dealing with "soft" paint trying to get the covers around the lights and back on the housings. Took some patience to be sure because I sure wanted to see how the final product looked all finished up. But knew it was best to be patient and wait it out.

Thanks again to @robmpii for a great idea and write up. Would not of thought fitting these awesome little lights in that tight space was possible without him forging the way. Really enjoy the look and function of these. Enjoyed working on them, and they've got to be my favorite "cool mod" now.

Looks like I nailed the up / down aim right out of the gate, and won't have to mess with them again. And the wide cornering pattern seems like it will definitely give me just what I want out of these.

Now for some pics!

Again, super pleased. Different, and look like they'll be very functional and give me exactly what I've been wanting for a long time....some good cornering lights!

Also ordered up and threw in some of Meso's ultimate turn signals while I had the mirrors off the truck. Tried to snag some puddle lights, but we all know how fast those went. Another time for those.

One of these days I'll be able to get back out in the sticks and put them to actual use. Until then, it's on to the next lighting mods....BD S2 Pro's in area / work scene pattern in the rear bumper and another pair for area / work lights in the bed of the truck. Got an idea for those!
Click to expand...

Clean

RushT · Jun 21, 2019

MESO said: ↑

Clean
Click to expand...

Hey meso, just found this thread and was wondering if you could mock up an insert cowl. You know, cut a hole and plug it with your insert for a clean look, then mount the lights to your insert.

robmpii · Jul 7, 2019

sagexp said: ↑

Didn't take progress pics since robmpii pretty much had all the bases covered.

Returned the S2 sports and decided to go with the S2 Pros. Trying out the sports at home and wasn't convinced they'd give the light output I was looking for. Besides, can't recall ever being in an off road situation where I thought to myself "ya know, I could really use a little less light here". So the Pros in wide cornering it was.

Took the factory mirrors off the truck and put on my replacement mirrors and factory mirror caps. Wasn't in a hurry (obviously since I've been tinkering with this for going on two months now on and off) and worked on this when I had some time to kill over four or five weekends, including painting, wet sanding, wiring, etc. Used the replacement mirror caps instead of factory caps, so I did have to paint the caps I cut up. Even if you were to use the factory mirror caps, you're still painting them otherwise the white plastic underneath will show when you cut into them.

Thanks to robmpii's pics, I knew just where the cutouts in the mirror caps needed to be to fit the lights within the housing, but with the twist of getting the lights more level versus following the bottom mirror cap contour line as rob did. Struggled with that decision for a while, but mocked it up with a couple S2 faceplates and double stick tape on my oem mirrors, and decided "what the hell, let's try them level."

Situated the light face plates on the caps, scribed out the cuts, and then outlined with masking tape. Got a rough cut out in the caps (about 1/8" shy of finished size), and then worked slow and patiently with a small battery operated Dremel on low to lowest speed and some small hand files. Using the S2 faceplate (grind, try to fit the faceplate in the hole, grind and file some more, repeat), finished up the fit until the lights just fit the opening, with just a hair of a gap or reveal around the lights so I wouldn't be possibly damaging or chipping paint pulling covers on and off to make final adjustments once installed on the truck.

Finished the cutouts, fitting, and painting of the mirror caps a few weeks ago. Was really happy with the fit and overall outcome. Unfortunately while wet sanding I slightly exposed an area of basecoat on an edge. Hardly noticeable, but being anal about such things and knowing this would ruin my enjoyment of the little project, had to start over, re-spray, clear coat, wet sand and polish the caps. My first attempt at a automotive finish with rattle cans, or really any automotive painting at all, but got them to come out right on the 2nd attempt.

Let the caps dry for two weeks, put them back on the mirrors, and got the mirrors installed and wired up today. Will wax them in a month or so. Very pleased overall.

The paint match for quicksand from automotivetouchup, well, not perfect. But it's pretty close, and I'm not re-spraying them again. I have some experience in finishing (fine woodworking), but I'm not a painter and this was my first attempt at a rattle can automotive finish, so after two attempts (1st one I wet sanded through the clear), I'm satisfied with the finish on this one, if not the color match. It is what it is. I'm more concerned with the fit and finish than I am the fact the paint is not quite a spot on match.

Picked up a can of the Rustoleum Gloss Khaki, and that was close as well, but a couple shades off on the lighter side. Seemed more "off" than the automotivetouchup was. Plus, that paint (Rustoleum) seems to take forever to dry to touch and off-gas, so I wasn't going to risk it. I may try that paint on the bumper caps though.

Not exactly an "easy" bolt on type project, but fairly easily doable if you have time, are not prone to rush things, like to tinker, and have patience. Very much worth the expense and effort (at least to me) to get a couple of lights on to light up the sides without resorting to a-pillar pods. Plus, once I saw robmpii's pics, I knew I HAD to have those!

Lessons learned;

1. Use enough coats of clear to be able to wet sand! I'm a newbie to rattle can and base coat / clear coat painting, so I wasn't aware of just how many decent coats it would take to give enough depth for wet sanding and finishing.

2. Remove BD S2 face plates when installing and removing modified mirror housing covers. The faceplate is slightly larger than the light body, and has a fairly sharp edge on the back of the plate which can mar or chip paint on edge of cutout. I found this out after my 1st paint attempt. But because I had to re-paint anyway due to sanding through the clear, no lasting harm done.

3. Get the light aim and orientation of the lights in the housing right before removing covers for last time for painting. This will help prevent accidental damage to paint from pulling and reinstalling cover multiple times trying to adjust the light aim, and also adjusting the light fit within the covers.

4. Once painted, wet sanded and polished, allow paint enough time to cure before messing with it again. I gave the covers 2 full weeks to cure out and harden before they even went anywhere near the housings again so I wasn't dealing with "soft" paint trying to get the covers around the lights and back on the housings. Took some patience to be sure because I sure wanted to see how the final product looked all finished up. But knew it was best to be patient and wait it out.

Thanks again to @robmpii for a great idea and write up. Would not of thought fitting these awesome little lights in that tight space was possible without him forging the way. Really enjoy the look and function of these. Enjoyed working on them, and they've got to be my favorite "cool mod" now.

Looks like I nailed the up / down aim right out of the gate, and won't have to mess with them again. And the wide cornering pattern seems like it will definitely give me just what I want out of these.

Now for some pics!

Again, super pleased. Different, and look like they'll be very functional and give me exactly what I've been wanting for a long time....some good cornering lights!

Also ordered up and threw in some of Meso's ultimate turn signals while I had the mirrors off the truck. Tried to snag some puddle lights, but we all know how fast those went. Another time for those.

One of these days I'll be able to get back out in the sticks and put them to actual use. Until then, it's on to the next lighting mods....BD S2 Pro's in area / work scene pattern in the rear bumper and another pair for area / work lights in the bed of the truck. Got an idea for those!
Click to expand...

Dude! Very nice work. I'm super impressed with your final product and couldn't be more psyched that you pulled the trigger and went for it. Looks fantastic. Take any pics inside the mirror cap?

Also, good choice on going with the S2 pros. How do you like the full cornering lens as compared to the combo?

sagexp · Jul 7, 2019

robmpii[OP] said: ↑

Dude! Very nice work. I'm super impressed with your final product and couldn't be more psyched that you pulled the trigger and went for it. Looks fantastic. Take any pics inside the mirror cap?
Click to expand...

Thanks! And I didn't get pics inside the cap or housing, though I wish I had. Would of been helpful for others I think to see how the cutout looks from the back of the cap. There's two prongs / clips in there that need to be retained, and I had to shave almost half of the center prong to fit the light and keep it level. But I was able to retain it, and the cover clips in very securely still.

(Using the Poway replacement mirror housing assembly for my notes here, but this housing won't work for BD S2's due to the configuration of the spring on this mirror. To fit the S2's, you have to go with the OEM housing with the spring assembly located in the underside of the housing.)

Inside of mirror cap before I modified. This is very close to how my final cuts came out.

I thought the other day I should have taken final pics of the inside of the cap for those who may attempt this in the future, but did not do so before I had it re-installed. And right now, don't want to mess with success. I'd be super bent if I messed up paint or broke a tab getting them back off and trying to take pics at this point!

Also, good choice on going with the S2 pros. How do you like the full cornering lens as compared to the combo?
Click to expand...

I didn't have a combo pattern to compare it to, but the wide cornering is perfect. No hot spots, and when I turn on the BD S8-20 light bar as well, I've now got this awesomely smooth full field of light for about 180* from the seats / mirrors forward.

Before I got them on I was contemplating going with a combo lense, and cutting off 1/2 of the standard reflectors (the two reflectors are formed as one piece inside the light) and replacing with a work scene reflector behind the clear lense portion of the combo lense for more dispersion of light to the sides. Don't think it is even worth messing with. I have the bottom of the beam hitting about 25' or so to the front of the truck. The residual light to the bottom and sides lights up everything brightly and nicely, the the rise of the main pattern throws light a good distance downfield.

This really is just what I was looking for in a cornering / ditch light. Props and thanks again for taking lead as test case on this! I couldn't be more pleased with how this works out and looks for what I wanted.

jdmdom · Jul 10, 2019

That awesome, great idea and easy to do. Props!

bunz559 · Aug 28, 2019

Great info folks! Awesome DIY!

Cody_89 · Sep 24, 2020

robmpii[OP] initial post: ↑

I've been getting requests for more info on a mirror-mounted ditch light mod I finished on my 2018 Tacoma earlier this year. I thought I'd get a short and sweet write up out there for anyone interested. I wished something like this was out there when I started!

This is not a terribly difficult mod to do, but it is time consuming and requires patience in finishing, achieve correct fitment, and aim. Not a simple cut stuff out and bolt stuff in job.

Some important things to note/think about: the two mirrors are mounted at different angles relative to the longitudinal axis of the truck. This means that the lights will be aimed similarly, but will never be exactly the same. It's hardly noticeable. Also, the lights are adjustable up and down... before final finishing. Any major change after that and you'd have to adjust the hole in the mirror cap. Lastly, I know it seems like a lot of material was cut away. It was. The mirror is still structurally solid.

Inspiration came in no small part from @mesojdm 's mirror-mounted Rigid lights. I imagine the process is pretty similar, with some more material removal for the larger size Baja S2.

I'm not responsible for any damage to you or your truck. Despite how this thread is written, this is a documentation of what I did, not a guide to repeat it. I'm going to focus only on what happens to/inside the mirror, as there's a lot of other info out there on wiring lights and finishing. Please let me know If I need to elaborate or correct anything.

Start by getting the mirror cap off. Get your fingers under the rim of the cap next to the turn signal and give it a gentle pull toward the front of the truck. Additionally, you'll want to remove the mirror glass and tuck the wires out of the way. To remove that, gently push on the top of the mirror to create a gap to get your hand in on the underside. Then, apply a pulling pressure from the center of the mirror. It's more than you think and the mirror will crack if you do it wrong.

Baja offers a template for the S2 on their website: https://www.bajadesigns.com/products/s2-pro-led-driving-combo.asp.

Print that sucker out and start going to town with a dremel. Take extra care not to touch the stock wires. Use cutting disks and grinding attachments to cut out enough material for the S2 to sit parallel with the bottom of the mirror cap and as low as possible to the floor of the mirror assembly. This is where the tedious trial and error fitment begins. Use the template to approximate the amount of material to be removed, then use the S2 with the bracket attached to sweeten up fitment.

Note the orientation of the S2 bracket. It must be mounted like this in order to be low enough. Any higher and when you cut the hole in the cap for the S2, you'll come close to cutting into the compound corner of the mirror cap. Also, do your best to get the bottom of the bracket to mount flush to the plastic support (where the bracket mounting hole is pressed against in this picture). You can do this by grinding away at the higher material, or using a spacer to make the low areas higher.

In order to actually mount the light to the mirror, you'll have to drill a hole for a bolt in the previously mentioned plastic support for a mounting bolt (red) , then a corresponding access hole that'll be used to access and tighten down the nut (blue). You'll also want to use a washer between the nut and the plastic (not pictured). Don't sweat the pro artwork.

Once you have the S2 fitted and mounted, pull it all out. Time to run some wires. Use the harness included with the S2 to cut a section of wire, including the connector for the S2, about 2ft long. Take the mirror housing off of the truck. There are three nuts attaching the mirror behind a trim panel inside the truck. Once the mirror is off, start cramming the positive and negative wires from the section of wire you cut down the hole pictured in yellow. There's plenty of room for two extra 16-18 gauge wires. Pull the wires through and into the cab, add additional sections long enough to get them all the way to the engine compartment, then route them through the door panel, through the rubber accordion tube that connects the door wiring to the cab near the foot well, then to the engine compartment. Wire up the lights.

After you've done all of that and wired the light, mount the S2 to the mirror again and aim it. As you can see in the completed pictures, to get a level aim you'll want to angle the light down slightly. If you can't, you'll have to go back and remove some more material to allow the light to move.

After wiring, mounting, and aiming the light, the only thing left to do is work on the mirror cap. First drill some holes in the mirror cap approximately centered where the S2 will be. Then, slowly work outward from there with a combination of more drilled holes, cuts, filing, melting, or whatever you need to do to make the cutout roughly match the shape of the light. Once that was done and the mirror cap fit loosely around the light. I had to sweeten up the fitment as I made my cutout a little too big. I did this first with a fiberglass impregnated bondo to bridge the gap, then standard bondo to make everything look nice.

Next was sanding and painting. I sanded the bondo and plastic down to 400 grit. Then I applied several coats of primer, color, and 2k clear from automotivetouchup.com. Their products worked out very well for me. The color match was spot on. Even the 2k spray clear self-leveled enough that I didn't need to wet sand.

Aaand done! Cool ditch lights in an understated, clean, oem looking package.

I'm happy to answer any questions you may have. I know some steps would have benefited from more pictures, but please let me know if there's anything else I can do to clarify. Happy chopping.
Click to expand...

Do you have part numbers for the mirror covers you used by chance? I've decided to undertake this myself and having tried and failed twice to get new covers from the dealer. Both times the mirror covers were wrong.

Tacospike · Sep 24, 2020

Cody_89 said: ↑

Do you have part numbers for the mirror covers you used by chance? I've decided to undertake this myself and having tried and failed twice to get new covers from the dealer. Both times the mirror covers were wrong.
Click to expand...

https://www.oempartsource.com/search?search_str=MIRRIOR

They will be different PN's for color finish

Cody_89 · Sep 24, 2020

Tacospike said: ↑

https://www.oempartsource.com/search?search_str=MIRRIOR

They will be different PN's for color finish
Click to expand...

I guess more specifically what I am trying to figure out is if my mirror (identical to the op), is the cover "without signal". For example my dealer order P# 87945-04050 unpainted and when I held it up to my mirror it seemed as if it would cover the led. But when I google searched the one "with signal" it looks completely different.

Which is why I was wonder exactly what P#'s the op used to order his.

tonered · Sep 24, 2020

Cody_89 said: ↑

I guess more specifically what I am trying to figure out is if my mirror (identical to the op), is the cover "without signal". For example my dealer order P# 87945-04050 unpainted and when I held it up to my mirror it seemed as if it would cover the led. But when I google searched the one "with signal" it looks completely different.

Which is why I was wonder exactly what P#'s the op used to order his.
Click to expand...

The Sport, OR, Pro, and Limiteds have the mirror turn signals. The SR and SR5 does not.

Is there a reason that you are trying to order covers? My assumption is that the @robmpii modded his stock ones?

Cody_89 · Sep 24, 2020

tonered said: ↑

The Sport, OR, Pro, and Limiteds have the mirror turn signals. The SR and SR5 does not.

Is there a reason that you are trying to order covers? My assumption is that the @robmpii modded his stock ones?
Click to expand...

Yes, I am taking the same approach he did and ordering another set to do this light mod. That way If I mess it up or decide to remove them later down the road I can put the unmodified covers back on.

sagexp · Sep 25, 2020

Cody_89 said: ↑

Yes, I am taking the same approach he did and ordering another set to do this light mod. That way If I mess it up or decide to remove them later down the road I can put the unmodified covers back on.
Click to expand...

The one the dealer ordered is the wrong one, and is for mirrors for the SR and SR5 without the turn signals in the mirrors.

Here's what I went with:

https://www.1aauto.com/products/i/1AMRP01878?trk_msg=AVTVC3M4C1P4P666NGN9A11484&trk_contact=KC88RPC4ONR10CCCH50DHTEPH4&trk_module=tra&trk_sid=J16V81RKV8RAOQFHE3MIFRNCPC&utm_source=Transactional&utm_medium=Email&utm_term=https://www.1aauto.com/products/i/1AMRP01878&utm_campaign=OrderConfirmation&utm_content=1A+Order+Confirmation

Since I didn't want to rush anything, and knew it would take me a while, I ordered the complete mirror with cover, and swapped out the complete mirror assembly. Unfortunately I found after I received the mirrors the mirror bodies I ordered would not work with this mod due to the location of the spring inside the mirror. So I then took the non-oem mirrors, and put them on the truck along with the oem mirror covers, and left those on for the 5 weeks or so of "here and there time" it took me to complete the mirror work . I then went to work on the oem mirrors and non-oem covers when time allowed, and at a much easier setting and pace (work desk / couch) than were I to have left them on the truck and attempted this.

For $150, it was piece of mind, and also leaves me a complete set of mirrors and covers to throw on the truck should I decide to sell it, yet keep my modified mirrors.

You might want to also consider a set of Meso's ultimate turn signals while you've got everything apart. Nicer look than the factory turns IMO.

nudavinci64 · Sep 25, 2020

MESO said: ↑

Well done sir. I was wondering how you flushed them when only seeing a front on pic.
What people don't realize why this is also the best spot for "ditch lights" is you can swing your mirror in manually for a much greater field of light. Throw in @KTJO 4x4 power folding mirrors and you essentially have an automatic spot light haha
Click to expand...

was thinking the same thing! great ideas

Heleo73 · Sep 25, 2020

Get a vin # from a Tacoma that has the turn signal mirror and color you are looking for .
Only that way they will give you the correct part you need.

Cody_89 · Sep 25, 2020

Heleo73 said: ↑

Get a vin # from a Tacoma that has the turn signal mirror and color you are looking for .
Only that way they will give you the correct part you need.
Click to expand...

Yup, already gave them my VIN and all and they still had to order 3 times. Ultimately had to order them pre-painted. I was able to get the first light installed today and I will finish the second tomorrow.

Heleo73 · Sep 25, 2020

Give them a vin from a Tacoma that has the parts you’re looking for.
I needed one mirror cover for Turn signal and I used the vin from a Tacoma that has the parts I’m looking for only that way they can give you what you need.
By any chance do you know where to get the Turn signal output to connect the wire ?
Thank you

Taco-Obsessed · Sep 25, 2020

Anyone seen this done on 2nd gen mirror? Or think the Baja S2s would or would not fit in a 2nd gen mirror? Really like this, plus being able to fold the mirror to point the light would be real useful for me.

Cody_89 · Sep 25, 2020

Heleo73 said: ↑

Give them a vin from a Tacoma that has the parts you’re looking for.
I needed one mirror cover for Turn signal and I used the vin from a Tacoma that has the parts I’m looking for only that way they can give you what you need.
By any chance do you know where to get the Turn signal output to connect the wire ?
Thank you
Click to expand...

That would be my VIN lol. Thankfully I got what I needed today. Unfortunately I don't know on the turn signal output, sorry.

Cody_89 · Sep 25, 2020

Taco-Obsessed said: ↑

Anyone seen this done on 2nd gen mirror? Or think the Baja S2s would or would not fit in a 2nd gen mirror? Really like this, plus being able to fold the mirror to point the light would be real useful for me.
Click to expand...

I've only seen it on the 3rd gens here in the forum. But that doesn't necessarily mean it can't be done.

Heleo73 · Sep 26, 2020

I might just take it to a shop just so they can find the turn signal out put I already wired it just need the output.
Thank You .

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