A few weeks ago in another thread, I mentioned designing a headlight filler panel that would house a Rigid Industries 6” SR series light. The reason I wanted to do this was to clean up the front end of the truck a little. I had four SRQ lights mounted on top of the bumper, but was never happy with the look there – too cluttered. These lights will be much more integrated into the truck, as opposed to just “stuck on”. Also, with the 6” lights, I will get a little better performance.
The lights will aim perpendicular to the filler panel, so they will be pointed slightly outward toward the sides of the road, which will be perfect to fill in the area between my driving lights and ditch lights. I completed the preliminary design last week. Then I had a prototype part 3D printed by @MTD. He was easy to work with and got the part built right away, and shipped it to me. The cost was very fair also.
I only had the passenger side panel built, because I fully expected to make some design tweaks. I cleaned up the part and began test fitting it. You will notice that I had to add some height to the panel on the bottom side, because the SR lights are a little too tall to fit in the panel. I’ll be using the spot lights that used to be on the front of my roof rack, before I replaced them with the 10” hyperspots.
Test fit on the truck:
For a part that is somewhat difficult to measure, I was pretty happy with how the prototype fit. Just needs a few adjustments.
This is the back side, showing how the light mounts:
With the light installed:
From the back side:
Installed on the truck with the light:
Overall, I’m very pleased with how this is coming out. There are a few minor changes I want to make for fitment, and a few flimsy areas that need to be beefed up. Otherwise it is really close. I will make the design changes and have MTD make the final right and left side pieces.
