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post #1 of 15 (permalink) Old 04-29-2007, 12:46 PM Thread Starter
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Installing Mopar driving lights: mounting issues

Has anyone here tried to install the Mopar off-road lights onto the Mopar brush guard? The crush fittings and instructions have got to be the worst design ever. I can't get the fittings to crush correctly and have rounded off the nuts and damaged to power-coating on the brush guard. Does anyone have any better ideas for installing these lights?

Off to do something easier: installing my Gibson exhaust!

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post #2 of 15 (permalink) Old 04-29-2007, 02:28 PM
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Re: Installing Mopar driving lights: mounting issues

What kind of crush fittings are they, is it what some call a blind nut?
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post #3 of 15 (permalink) Old 04-29-2007, 02:56 PM Thread Starter
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Re: Installing Mopar driving lights: mounting issues

Yes, that's what I have. The instructions say to insert the blind nut, thread the regular nut onto the bolt, thread the bolt into the blind nut, tighten the regular nut against the blind nut, then tighten the bolt to crush the blind nut into place. However, when I tighten up the bolt, it tightens up against the regular nut and won't go any further, preventing the blind nut from crushing. I've destroyed the original hardware so I have to get some new stuff. I also think that the bolts are too short as the lights are a multi-vehicle use set, so a set of longer bolts would help.

When I've dealt with these in the past, there's usually a small tube or similar with a shaft that threads into the blind nut, then tube goes over the shaft, a nut threads on the exposed end and then you tighten that, crushing everything into place. I might hit Lowes or Home Depot and see if they have something like that; Rack Attack might also have something in stock.

Any suggestions please post them here.

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post #4 of 15 (permalink) Old 04-29-2007, 03:59 PM
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Re: Installing Mopar driving lights: mounting issues

What's important with using blind nuts is the tapered part that spreads and holds the blind nut till it compresses.
Typically, we use a air gun with an allen bolt in it and a tapered end around the allen bolt.


Here's some hand tools


Auto parts store sometimes carry the blind nuts and tool in their specialty section.
Lowes or Home Depot might also have them.
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post #5 of 15 (permalink) Old 04-29-2007, 07:49 PM Thread Starter
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Re: Installing Mopar driving lights: mounting issues

Cool, that's the info I needed. I don't have any blind nut tools and the kit doesn't come with one. I bought some rubber expansion nuts but would rather use what the kit specifies. I'll hit my parts store this week and see what they have.

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Re: Installing Mopar driving lights: mounting issues

Can anyone advice how to get a cable thru the firewall and inside the vehicle to install the switch?
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Re: Installing Mopar driving lights: mounting issues

Quote:
Originally Posted by Dabitz
Can anyone advice how to get a cable thru the firewall and inside the vehicle to install the switch?
I remember seeing a hole with a rubber membrane in the firewall near the drivers side. I don't have time at the moment, but I could try and snap a picture of it. I think I remember another thread where someone talks about using it to run wiring through...
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post #8 of 15 (permalink) Old 04-30-2007, 07:23 AM
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Re: Installing Mopar driving lights: mounting issues

There should be a few things going through the firewall with a rubber grommet, like the shifter cable, accelerator cable (3.7) etc. Find one you can get to from both sides and if there's not enough room to slide the wire in the existing hole, make a new hole in the rubber grommet.
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post #9 of 15 (permalink) Old 04-30-2007, 07:35 AM Thread Starter
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Re: Installing Mopar driving lights: mounting issues

Quote:
Originally Posted by YB Normyl
There should be a few things going through the firewall with a rubber grommet, like the shifter cable, accelerator cable (3.7) etc. Find one you can get to from both sides and if there's not enough room to slide the wire in the existing hole, make a new hole in the rubber grommet.
Also, use a coat hanger or wire snake to thread the wiring through the grommet, it'll make life much easier.

Dabitz, did you get the lights installed on the brush guard? Or are you not using the Mopar brush guard?

2006 XK Sport, 4.7l, QTII- many mods
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'An armed society is a polite society. Manners are good when one may have to back up his acts with his life."- Robert A. Heinlein

"Men sleep peacefully in their beds at night because rough men stand ready to do violence on their behalf."- George Orwell



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post #10 of 15 (permalink) Old 04-30-2007, 08:29 AM
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Re: Installing Mopar driving lights: mounting issues

Quote:
Originally Posted by rwmorrisonjr
Also, use a coat hanger or wire snake to thread the wiring through the grommet, it'll make life much easier.
And wrap all wire in wire loom to protect the wire and give it a professional look.

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