Hello all, I have been lurking around this forum on and off for the last couple years since I bought my 2004 SR5 4runner. I really love the car and I have finally found the time to finish some projects that have been in the works. I thought I would share one that I thought was pretty cool.
My goal was to fabricate a high output lighting system at a reasonable cost that does not change the appearance of the car. I like the look of solid rig, but a bone stock 4runner with only a huge light bar is not my personal taste. There are plenty of lighting options out there, but none that implement compact design with liquid cooling. In other words, a 200w LED system implies a large fixture, typically several feet in length. The primary hurdle in LED technology is thermal management. The large fixtures utilize passive air cooling with heat sinks that make up a majority of the fixture. I designed a system to overcome the issue of thermal management that can be retrofit into the stock fog light housing.
I removed the stock fog light collimator and lens. The stock optic seemed of poor quality (maybe just old) and appeared to have a beam angle of approximately 90-120 degrees. They had the stock halogen 55w bulb and really didn't do much for me in low vis conditions.
Each housing I re-fit with 100 watts of LEDs and upgraded the optic to a 60 degree beam angle. The manufacturer rates this at a total of 20,000 lumens. I won't get into the lux/lumens debate and "exactly how many lumens" is typically a pissing contest anyway. The fact is, they are quite bright and work amazing as fog lights.
The system draws about 20A, so I don't run them much with the car off. The other downside is that they are by no means street legal, nor would I want to use them on the street so long as there is oncoming traffic. Looking into them is like looking at a laser beam, it is very hard on the eyes. At best it would be a huge nuisance, at worst would cause an accident. On the other hand, I have some monster fog lights. The camera just doesn't do it justice.
Anyway, this was a fun project and I thought I would share. Let me know what you guys think.