Door reflector LED mod step by step
 

Well I decided to do my own LED door reflector mod. The following is a step by step.

Enjoy.
Step #1 Remove lense from Door panel

Wrap a protective cloth around the tip of the regular sized screwdriver, and push the tip into the slot at the bottom of the door reflector. Start with the tip pointing upward and then pivot the screwdriver handle upward slightly toward you which will push the tip into a more horizontal direction into the door, there by prying the door reflector upward and away from the door panel. There are two tabs on the top and one on the bottom in the center. That is the one with the body clip on it.

#2 put the reflector in the vise via the two top taps as a gripping spot and get the dremell tool ready with a thin cut off wheel.
http://i258.photobucket.com/albums/h...1/DSCF0375.jpg

#3 There is a grove all the way around the entire lense between the backer plate and red lense. This is where you will cut with the dremell tool.
http://i258.photobucket.com/albums/h...1/DSCF0374.jpg

#4 Take your time and do a few inches at a time letting the wheel cool between cuts. If the wheel gets to hot it will melt instead of cut:ack:
A half inch is all you have to go down as far as the depth of cut.:thumbs:
#5 Flip the lense the other way up and sandwich between a cloth. An old pair of underware works great:lol:

Continue cutting the other side.

http://i258.photobucket.com/albums/h...1/DSCF0377.jpg

#6 Once the cut is complete all the way around the two pieces will come apart very easy.http://i258.photobucket.com/albums/h...1/DSCF0372.jpg

http://i258.photobucket.com/albums/h...1/DSCF0373.jpg

#7 clean off the rough edges with a sander.

http://i258.photobucket.com/albums/h...1/DSCF0379.jpg

http://i258.photobucket.com/albums/h...1/DSCF0380.jpg

#8 Sand the lip smooth on the backside of the lense. It must me smooth not only for the glue but any inperfections can be seen. I used a piece of sandpaper on a table to smooth things out. I went down to 300 grit to get a great finish.
http://i258.photobucket.com/albums/h...1/DSCF0381.jpg

http://i258.photobucket.com/albums/h...1/DSCF0382.jpg



#9 I painted the backers flat black. Since the LED ribbon is black this should hide it well. Plus it makes the reflector look just a little darker. I like it darker cause my door panels are dark.
http://i258.photobucket.com/albums/h...1/DSCF0383.jpg


#10 Ok once you get the ribbon LED take off the end that lets you pigtail to another LED strip. You do not need to pigtail.

http://i258.photobucket.com/albums/h...1/DSCF0395.jpg


http://i258.photobucket.com/albums/h...n0591/3446.jpg


http://i258.photobucket.com/albums/h...1/DSCF0396.jpg

#11 Drill a hole on the top right side big enough for the plug to fit through.
http://i258.photobucket.com/albums/h...1/DSCF0397.jpg

#12 Run the plug through the hole and lay out the LED strip.
http://i258.photobucket.com/albums/h...1/DSCF0398.jpg

#13 Once everything fits remove the 3M tape backing on the LED. Press down on the strip to tape it to the backer plate. Make sure you go slow and it is straight.
http://i258.photobucket.com/albums/h...1/DSCF0400.jpg

#14 Test the LED with 12 volts before this next step::::::::::The solder contacts at the end need to be covered with a little piece of electrical tape before you coat it in silicon.
Take the backer plate and apply a good bead of clear silicone sealant.
http://i258.photobucket.com/albums/h...1/DSCF0406.jpg

http://i258.photobucket.com/albums/h...1/DSCF0407.jpg

#15 Install the Red reflector on the top of the backer plate and keep pressed together. I used a pair of mini bottles. Also add a dab of sealant around the wire coming out of the backer plate. You can cut off the extra sealant with a razor blade once it cures.
http://i258.photobucket.com/albums/h...1/DSCF0408.jpg

#16 You are done!!!!! Hook up to 12 volts and enjoy.

I will post picks when it is installed. The following picks don't do the mod justice. These LED's are super bright. If you don't want to go so bright order Red LED strips.

http://i258.photobucket.com/albums/h...1/DSCF0403.jpg

http://i258.photobucket.com/albums/h...1/DSCF0404.jpg

http://i258.photobucket.com/albums/h...1/DSCF0405.jpg

http://i258.photobucket.com/albums/h...1/DSCF0523.jpg

Looking forward to seeing the finished pics :thumbs:

Chuck

Great write up so far, keep the updates coming. :thumbs:

Cant whate

Hmm look familier.
Looks good so far.

Looks great, can't wait to see the finished product

Feel free to chime in if you see me doing something wrong :lol:

Very cool project. Will be following this thread as you go along.

I am going to do the wiring for the puddle lights and reflector this weekend. I am on a stand still till the LED ribbons for the reflectors show up.:crazy:

So far so good!

You've been working on this since January of '09 and this is as far as you've gotten? Boy, I thought I was slow! LOL

Sorry, I couldn't resist :rofl:

subscribed

:lurk::cheers:

Dang I did it again:lol:

:banghead: :banghead: :banghead:

:thumbs::cool:

:lurk:

Doing the puddle lights I may tackle this one at the same time. Looking forward to seeing the results.:thumbs:

I also bought some cool white LED strips to replace my footwell lights :thumbs:

I have lots of stuff to wire up :cheers:

Keep a 2.5lb Halotron handy. :lol:

:lurk::lurk: