Switch's flush mounted Baja Designs S1 cornering lights at 45°

This project was to add Zone 2 lights to my Tacoma. The idea is to illuminate to the left and right while cornering on dark trails. Also, to create 180° field of view: filling in the sides where my LED Light bar fell tapered off.




https://www.bajadesigns.com/help/lighting-zones/

I considered using A Pilar mounts but I didn't want glare on my hood or anything that would obstruct snow removal from my windshield.







My solution was to flush mount Baja Designs S1 lights at 45° on the corners of the body above my bumper.



I designed a flush mount that fits this location using FreeCAD software and printed it using my Prusa MK3S printer.


Due to he complexity of the shape of this corner of the body, this was way harder than you'd expect.

Test fit



After carefully positioning the mount, I drilled the four corner holes and temporarily installed the mount so I mark the corners that I would need to cut out to flush mount the Baha Designs S1 LED Light. Then I removed the mount.



Then I very carefully cut out the hole for the light




After I cut the hole for the S1 I used a file to round out the hole (not shown)


Here's my first draft of the mount (my latest version is about 5mm thinner).



I added the cornering lights to the switch I already installed for the Bumper Light Bar (so that switch controls three lights at once):


I also added these lights to my center console switch panel that controls each light independently. In this case the upper left and right switches control the each cornering light separately. I used diodes in line from these switches to isolate each of them from the Bumper Light Bar switch in my dash.




Here is the finished install:


[edit]

Here's an updated video showing the efficacy of the cornering lights:
https://www.youtube.com/watch?v=Hq06zH8fCMg

 

Nice, are ya going to do the turn signal tie in, or is it too much light on the street?
Or worst, CHP gonna give you shit?

 

Pretty cool. How’s the light when in use?

 

Really nice work. I’m sure those will come in handy. Bravo.

 

Interesting -- any reason you chose this location as opposed to adding cutouts to your bumper?

 

I would of done bumper as well. Would gave it a cleaner look.

 

Nice mod! My wife's RX350 has factory cornering lights and they're a very nice feature to have. The Lexus ones are so trick that they turn on when you signal or turn the steering wheel!

Also, kudos to the BD marketing folks, look at all the lights that you NEED! Very smart way to educate the customer and create sales.

 

any reasom why you cut your bumper for this? it looks like that light has the same trajectory as my dirch lights...

 

I wouldn’t call them “flush mount” but they do look better than just bolting them to the plastic.

what material did you print your housings out of?

 

I just mounted s2 pros at 45* on the outer most punts on my hybrid bumper, that was my solution.
My ditch lights are redundant but i have them in clear and my bumper lights in amber.
I also dont notice any issues when clearing snow off my hood with the ditch lights, just cant go to town with the scraper, have to be a little gentle when near the lights

 

Nice, I appreciate your choice to do something different.
Ditch lights work fine for me, never had a problem with snow removal.

 

Very clean and thought out the installation. This turned out really good from the original idea you had weeks ago that most people shot down.
Best,
Brandon

 

The point on the bumper that is at 45° is the spot most likely to hit something. I figured the location just above the bumper was more protected.

 

Yeah, as flush as I could get them in that location.

This is PETG plastic.