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  #261  
Old 04-11-2024, 04:00 PM
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looks great, but needs an additional part...

Quote:
Originally Posted by Henn28 View Post
...The CSF cooler is exceptionally heavy duty, and has survived one "gentle" rear-end accident, courtesy of my daughter, but I'd like a bit more....



Much more secure solution that I'm pretty happy with. ...
If I were you, I'd not feel secure with the radiator exposed, without a stone guard of some sort of mesh, at least to intercept and/or deflect at least some of the stones, aggregate, and smaller road debris that are on our roads. There are plenty of suppliers that make these for circle racing, and I've seen a few on street/strip drag cars that used a separate transmission cooler ( didn't need one on mine, as it was mounted behind a headlight bucket, after I replaced it with a dual hi/low lamp, but still used a light mesh screen to prevent a bug build-up).

While driving since 1965, I've had a billion stones damage my vehicles, a lower radiator hose and later, a radiator, pierced by road debris. “An ounce of prevention is worth a pound of cure.”
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  #262  
Old 04-12-2024, 02:40 PM
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Quote:
Originally Posted by workingonit View Post
If I were you, I'd not feel secure with the radiator exposed, without a stone guard of some sort of mesh, at least to intercept and/or deflect at least some of the stones, aggregate, and smaller road debris that are on our roads. There are plenty of suppliers that make these for circle racing, and I've seen a few on street/strip drag cars that used a separate transmission cooler ( didn't need one on mine, as it was mounted behind a headlight bucket, after I replaced it with a dual hi/low lamp, but still used a light mesh screen to prevent a bug build-up).

While driving since 1965, I've had a billion stones damage my vehicles, a lower radiator hose and later, a radiator, pierced by road debris. “An ounce of prevention is worth a pound of cure.”
I’ll see if CSF makes anything for it. Thanks for the tipper.
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  #263  
Old 04-27-2024, 09:08 PM
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Lights and clamps showed up and I had a few minutes to bolt them up. Initially I envisioned them hanging down from the bar, but I think this looks better, and I’m not sure they are weather proof installed upside down.


Next job is to wire them up.
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1993 Mopar 318 Jeep Grand Cherokee - original owner
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1996 BMW Z3
1998 BMW E36 M3 Sedan
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Last edited by Henn28; 05-17-2024 at 07:25 PM.
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  #264  
Old 05-17-2024, 07:24 PM
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wiring complete

I'd procrastinated enough so between rain storms today I wired up the KC Rally 400 halogen lights previously installed. They are 4" lights, which I felt would be plenty, and not overly out of place on the X5, but they may be a bit small. Fortunately the hard work is done and swapping them out should be easy. I like the 4" lights as the bodies are powder coated aluminum. Most other 6" lights by KC, Hella, etc. have plastic bodies.

My initial thought was to have someone 3d print an insert for the ashtray that would hold a rocker switch and the two USB plug ends to/from the audio head unit that currently terminate in the ash tray. A bridge too far for my one brain cell. Fortunately the switch that comes with these KC lights fits perfectly in the cigarette lighter frame, once it is drilled out.

The wiring harness for the Rally 400 lights doesn't have a relay (initially I thought it did), but rather a 15 amp fuse in line. The harness has a convenient plug in the middle so I was able to route and plug in the lights, then route the other half of the harness from into the car via a convenient hole (plug had long ago fallen out) next to the hood latch cable firewall hole.

Staying on this side of the car allowed me to connect directly to the battery at the terminal post by the brake booster, and the negative jump terminal by the oil filter housing. Then it was just a matter of plugging the two halves of the harness together and doing some clean up with with zip ties and wire conduit. I ran the wires out of the cowl at the rubber plug on the left side that allows a large wire bundle and the hood cable to exit into the engine bay. Still a little clean up to do with the routing and tiding up under the hood.

(wire conduit cleans it up somewhat, but I need to sort out that ugly power wire. Its not quite long enough so I will splice in a longer length and route it out of the way I think)


Pulling the covers under the steering wheel and the carpeted cover along the tunnel allowed me to run the harness up to the back of the cigarette lighter and make the connections. with the bottom of the metal housing completely drilled out, the 3/4 switch and 3x connections fit nicely.


They are on a hot bus right now being wired directly to the battery terminal. the switch lights up though when the are on, and I also ran a wire to the passenger side cigarette lighter (which I think is switched power) so I can more easily wire a relay in if I want larger lights or the added protection of no power with the ignition off.
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Original owner 2002 E53 X5 4.4i to 4.6i swap
1993 Mopar 318 Jeep Grand Cherokee - original owner
2015 V6 Jeep Grand Cherokee - the nice car for my wife
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1986 Saab 900S
1996 BMW Z3
1998 BMW E36 M3 Sedan
2004 BMW E46 M3
2006 Audi A3 Quatro
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  #265  
Old 05-18-2024, 06:21 AM
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Quote:
Originally Posted by Henn28 View Post
I'd procrastinated enough so between rain storms today I wired up the KC Rally 400 halogen lights previously installed. They are 4" lights, which I felt would be plenty, and not overly out of place on the X5, but they may be a bit small. Fortunately the hard work is done and swapping them out should be easy. I like the 4" lights as the bodies are powder coated aluminum. Most other 6" lights by KC, Hella, etc. have plastic bodies.



My initial thought was to have someone 3d print an insert for the ashtray that would hold a rocker switch and the two USB plug ends to/from the audio head unit that currently terminate in the ash tray. A bridge too far for my one brain cell. Fortunately the switch that comes with these KC lights fits perfectly in the cigarette lighter frame, once it is drilled out.



The wiring harness for the Rally 400 lights doesn't have a relay (initially I thought it did), but rather a 15 amp fuse in line. The harness has a convenient plug in the middle so I was able to route and plug in the lights, then route the other half of the harness from into the car via a convenient hole (plug had long ago fallen out) next to the hood latch cable firewall hole.



Staying on this side of the car allowed me to connect directly to the battery at the terminal post by the brake booster, and the negative jump terminal by the oil filter housing. Then it was just a matter of plugging the two halves of the harness together and doing some clean up with with zip ties and wire conduit. I ran the wires out of the cowl at the rubber plug on the left side that allows a large wire bundle and the hood cable to exit into the engine bay. Still a little clean up to do with the routing and tiding up under the hood.



(wire conduit cleans it up somewhat, but I need to sort out that ugly power wire. Its not quite long enough so I will splice in a longer length and route it out of the way I think)





Pulling the covers under the steering wheel and the carpeted cover along the tunnel allowed me to run the harness up to the back of the cigarette lighter and make the connections. with the bottom of the metal housing completely drilled out, the 3/4 switch and 3x connections fit nicely.





They are on a hot bus right now being wired directly to the battery terminal. the switch lights up though when the are on, and I also ran a wire to the passenger side cigarette lighter (which I think is switched power) so I can more easily wire a relay in if I want larger lights or the added protection of no power with the ignition off.

Nice!!
Have you considered the LED lightbar for in between the KC's?

Insanely bright and almost cancels shadows when in line with the bar.

Sent from Embassy network using Tapatalk
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  #266  
Old 05-18-2024, 08:42 AM
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Quote:
Originally Posted by EODguy View Post
Nice!!
Have you considered the LED lightbar for in between the KC's?

Insanely bright and almost cancels shadows when in line with the bar.

Sent from Embassy network using Tapatalk
I went cheap! Halogen’s are super cheap, and I thought I liked the smaller 4” look. I might end up going with 6” lights in the future, but will live with these for a bit to see how they do.
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Original owner 2002 E53 X5 4.4i to 4.6i swap
1993 Mopar 318 Jeep Grand Cherokee - original owner
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1996 BMW Z3
1998 BMW E36 M3 Sedan
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2006 Audi A3 Quatro
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  #267  
Old 05-18-2024, 10:16 PM
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Quote:
Originally Posted by Henn28 View Post
I went cheap! Halogen’s are super cheap, and I thought I liked the smaller 4” look. I might end up going with 6” lights in the future, but will live with these for a bit to see how they do.
Nothing wrong with that and it looks good with the KC's. I never looked at the cost for the bars, I'd only seen them turned on and could damn near see my whole skeleton through my body at a desert trip so that's why I brought it up.

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