DIY - Hella 500 Black Magic - Behind The Grill Mount

Finally have got the Hella 500's mounted behind the Satoshi.
Thanks to Klipp for his write up especially with how he made the mounting bracket.
If you haven't read his write up and are planning to do this mode I suggest you read it:
http://www.tacomaworld.com/forum/lighting/79832-hella-500-hid-conversion-mount-behind-satoshi-how-w-pics.html

I for the most part followed his directions on the bracket but did make a few minor tweaks (see below). I'll try to make this write up as detailed as possible and will go back and take some more pics and keep updating it as time permits.

Hood latch with the cover removed (very simple two bolts on either side of the latch cover). The bolt in the centre right below the hood latch is one of the mounting points for the bracket.


There are a few points that stick out from the hood latch that get in the way of the mounting bracket sitting flush against the centre support beam. Klipp mentioned that he cut these off. I didn't have an angle grinder or sufficient cutting wheel and preferred to make no permanent mod's to the truck so I improvised.

Holding the angle iron in place I marked the contact points with a fine tip permanent marker:


Then cut them out with my dremel's cutting wheel:


Filed things down slightly to get a good fit and drilled the centre hole through which the centre bolt below the hood latch would pass. Problem encountered again...the diameter of the bolt head was too close to the inner top angle of the angle iron for it to pass through straight. Again not wanting to drill new holes in the centre support beam I marked out the top of the angle iron with the pen and cut away with the dremel so the bolt could clear and pass straight through:


Bolt clears and did a test fit mounting the bracket with this bolt alone.

Next lay a level flat across the top of the bracket and square it up as best as you can.

Next is to make the L brackets which will be the outer supports.

Klipp made these by cutting the ends off the angle iron. I found that the angle iron was just barely long enough to reach the outer mounting bolts and if used I was going to have to drill the hole very close to the top of the L brackets. I picked up a couple of steel L brackets from the hardware store that were longer and would reach the mounting points a little easier. With the angle iron bracket level gently sit the L brackets on the outer edges in line with the top mounting bolts. Mark all the mounting points with the permanent marker. Drill holes and secure outer L brackets to angle iron using locking washers and nuts.





Mount the bracket: (picture jacked from Klipp's write up as I unfortunately didn't take too many while I was doing this)


Mount the lights and replace the grill!

When I battle with fitting the DDM H3 HID kit on these lights I will take some more pic's of the mounting points I refer too and do a more complete install guide start to finish.

For now the finished product:



FYI the mesh on the satoshi is from Custom Car Grills. It came perfectly cut and powder coated black and I know many on here have used this same mesh however it is far more transparent that I want. I have darkened things up back there slightly with some black rattle can but I don't want to go heavy on the paint. Will be looking at picking up a Grillcraft at some point and satoshi'ing it.

BLH's to come and black chrome ebay OEM lower fogs to follow in a couple weeks.

epa4wd and 84Hilux thanks for your help with the wiring...I will be adding this to the write up soon.

Few more pics:

No lights on:


Headlights only:


Headlights and Fogs (35W, 3000K DDM Raptor HID Kit)


Headlights, Fogs, Hellas:


Running lights:


Headlights:


Headlights and fogs (35W, 3000K DDM Raptor HID kit)


Headlights, Fogs, and Hellas:

 

that looks great man.. nice writeup

 

Looks great! I just got done making this bracket the other weekend. My old mounting method was allowing the lights to shake like crazy when offroad. With the new bar it is rock solid. Update when you get the DDM HID kit installed. I plan to use the same kit

 

nice job dude.

OP, show the black magic w/o the grille! the lights pictured w/o the grille are regular 500s - the black magic 500s are very cool and i'm not sure how many people actually understand what they look like unlit and unobstructed.

great light, IMO.

 

I'll post some pics of the Black Magic's with the grill off next week when I put in the black chrome lower fogs I bought on ebay. Have the 35W, H10, 3000K kit from DDM and am just waiting for the fogs to arrive. Can't wait to put them in!! Truck is pre wired and I picked up an OEM switch any relay on ebay so should be a really quick install.

Unfortunately I ordered the H3, 55W, 5000K kit from DDM which I thought would work. The bulb is too long to work with the Black Magic because of the internal black plastic so I am going to have to figure something out. I have found some H3C (compact HID) bulbs that I think will work on eBay fro 16.99. Only problem is they are 35W, 6000K and doesn't seem to be a 55W version of the H3C around. Meaning I will have to try and exchange the 55W balasts for some 35W ones. I have heard the horror stories of DDM customer service and sure enough I have to go and make this screw up on my first purchase from them. Wish me luck in exchanging them for 35w's!

 

Thanks!

 

If anyone wants to buy my DDM H3, 55W, 5000K Raptor Apex kit for the price I paid (about $35 let me know). The kit is brand new, never used or installed and purchased about two weeks back. PM me and I can assure you I'm not going to rip you off on the sale.

 

Looks Great!!!

 

made mine out of unistrut

 

nice i like.

 

Looks good, I like the smoked lenses a lot

 

Can you set these to switch on when hi-beams are switched on?

I am obsessed with light at night (not the best eyes) and want more! I have HID fogs and heads and did the 'fog lights anytime' mod so those stay on when the hi's come on.

I'm pretty sure it's illegal to use aftermarket lights on the road...correct??? But if I only use them with my hi's engaged, who cares? I only use my hi's on back roads when no other cars are around so no one would even know.

Thoughts?

 

You may be able to tap them into the hi-beam harness to get power when the highs are on, and run them off of a relay or something. I just have mine on a separate switch altogether so that I can have them on alone, or with my other lights

 

yes, of course.

and,

aftermarket lights on your vehicle generally are not illegal if wired/used properly as per the laws, but it depends greatly on your state and local laws.

 

i have them wired seperatly so i can have them on whenever

 

Bump, some more pics added.

 

Did you ever get the black magics converted to HID? If so where did you get the kit?

I was hoping DDM would have an H3C option available that wasn't listed on their site...but nope

 

I already got my hellas installed and will start the wiring process and have an oem fog switch. How did you wire yours and how would i wire mine?