Tail light installation

[dougkirkbride]

Did you all use a 4" hole saw for the tail light? Manual doesn't specify, but it appears a 4" would work nice. The manual does specify to use a 1-3/4 for the turn/reverse light.

[AZPete]

Rather than buy a 4-inch hole saw, I drew a circle with a compass and then cut on the line with a Dremel bit. It's not difficult to follow a line closely if you keep the tip of a shop vac hose close to suck up the dust so you can see the line. Smooth the edge with sand paper. It's a useful technique for other places on the body so perhaps practice on a scrap until you are comfortable.

[Wayne Presley]

I use a 4" hole saw.

[Pearldrummer7]

I too used a hole saw. Worked great

[Bob_n_Cincy]

I used a peanut butter jar lid that fit the hole perfectly. It had a mold mark in the middle that made it very easy to put a pilot hole. Then used the hole saw.
In this video you can see the my high LED tail light turns on much faster than my standard bulb brake lights.
I need to upgrade my tail light bulbs to LED.
Bob
Here is info on the taillights.

http://static1.squarespace.com/static/55144804e4b021a56f31ce24/t/55944853e4b0c83b4923b413/1435781203347/003-6020ProductInfo.pdf

http://www.commandelectronics.com/shop/command-spherical-incandescent-12-volt-tail-lights




https://youtu.be/SOJUZ8jr6MI

[UnhipPopano]

Is the documentation incorrect in how the light is installed? It shows the unit slid through the hole and mounted by #10 screws. While the instructions show the hole already done, as long as the unit fits through and there is enough material for the screws to go through, the red plastic lens will cover the hole. It should look the same from the outside if a 4 inch hole saw is used or a jig saw or a flexible shaft or any other method of making the hole. So what advantages does the purchase of a 4 inch hole saw have other than saving a little time?

[dougkirkbride]

Thanks all for the info, I think I will see if I can borrow a 4" hole saw, if not I will be cutting my own by hand. Also Bob, thanks for the light lens info, just in case I break one.

[longislandwrx]

I have a 4" carbide grit drywall hole saw. I wonder how it would work with fiberglass. I will have to find a scrap to test with.

[RM1SepEx]

I used a 4" hole saw

be careful with the screws, they are a bit large for the holes on the blinker/backup combo light and will break the molded plastic

[Buzz Skyline]

Is the documentation incorrect in how the light is installed? It shows the unit slid through the hole and mounted by #10 screws. While the instructions show the hole already done, as long as the unit fits through and there is enough material for the screws to go through, the red plastic lens will cover the hole. It should look the same from the outside if a 4 inch hole saw is used or a jig saw or a flexible shaft or any other method of making the hole. So what advantages does the purchase of a 4 inch hole saw have other than saving a little time?

Mostly time, but also less exposure to the nasty fiberglass shavings that come from most other ways I can think of to cut the hole, and reduced likelihood of measurement or cutting errors.

[STiPWRD]

I also used a hole saw. $14 from Harbor Freight (with coupon):
http://www.harborfreight.com/34-in-5-in-carbon-steel-hole-saw-set-18-pc-68115.html

Only took a few seconds to have perfect circles cut out, also used it for the gas filler hole, well worth it!

[Aero STI]

One more vote for the Harbor Freight hole saws. They're not the greatest quality, but work perfectly fine for fiberglass.

[wleehendrick]

One more vote for the Harbor Freight hole saws. They're not the greatest quality, but work perfectly fine for fiberglass.

meh... the quality must be inconsistent. I tried the HF hole saw kit and was really disappointed. When cutting out my taillights, all the 4" one was able to do was score the gelcoat. It made a nice circular guide for me to finish it off with a dremel, though!