How to: LED Light bars in turn signal location on ARB Deluxe Bull Bar

I posted some pics earlier, but wanted to do a write up on this project. I didn't like the looks or purpose of turn signals in the ARB Deluxe Bull bar I put on my truck, and didn't want to fool with wiring them up. I found a smoking deal on some LED light bars on Amazon and bought them. After I looked at them, I thought they might fit in the opening. So, I fooled around with it and got them to install pretty well.

The lights I used were Kawell K5-5118's. I got them on sale for $8 a piece. They appear well-made, are housed in aluminum, got great reviews, and are IP67 waterproof. Their dimensions are 6.2 x 2.1 x 1.7 inches.

First step: use a sharpie to trace around the opening of the turn signal hole:



Remove the traced portion, including the marker line. There are obviously plenty of choices for this, but I just used the dremel and a cutting bit. I ended up with a better final product, but didn't take a pic. You get the idea.



To get a flush fit between the lens and the front of the light, I ground that little stud that the screw goes through off.


Next, I fit the cutout lens over the light. It is a tight fit, but they'll go over the light. I used a drill bit placed through the screw holes to mark the front of the light housings. Then, I drilled through the side of the face of the housing, from front to back. I kind of angled the holes to match the angle of the edge of the housing. I just eyeballed it and it came out OK. I used a drill bit that was a little bigger than the ARB-supplied screws, I think it was 9/64.





One tip - see the little pillars on the columns that the screws go through on the sides of the opening, that hold the light assembly together? Leave those alone. I ground them off the first side, thinking it was required. It isn't, and you get a more properly-aligned final fit if you leave them, because they help keep everything lined up.




Once the holes were drilled, I realized the screws from ARB that hold the original light together aren't long enough. I ended up just using some drywall screws, so it shouldn't be too hard to find replacements. The cooling fins on the back of the light got in the way of the screw heads, so I ground some off with the dremel.


This is the hole before any grinding.


With a little ground out to make the screw head fit.


I colored the ground edge of the lens with a black sharpie to kind of make it blend it. I doubt it lasts very long, but I liked the way it looked.



Then I screwed it all together. The screw goes in from the back of the light and anchors into the original screw hole.

Finished product:


I used the flood lights, but they are available in a spot format. I wanted them to shed extra light toward the ditch to help see deer and such, and they excel at that. The angle at which they point is good for this. I may put some spacers in to shift the beam a little bit more toward the outside of the truck and then apply some silicone to fill the gap, but overall I am pleased. I also think they'll be good for fog with how low they sit, but they might shine up too high. I will update the thread as I use them more.

The light output is pretty good. With the ARB fogs and headlights turned on, it fills a void left by them and has an effect with both high and low beams. Overall, I am pleased with it. Total cost including lights, wiring harness, switch, etc., was under $50, and I used MIC switch and harness, so you could do it cheaper. Total time was 2-3 hours, and most of it was figuring things out with the first light. I did the second light in maybe 15 minutes.

Let me know if you have any questions or if something needs clarified.