Photos of 986 with the front bumper off

[beater986]

Originally Posted by itsnotanova

Are you dead set on having oval lights? If not than maybe a light bar might be easier to mount and lighter. I have a feeling that those lights will stick out farther than you expect. The weight and distance from a sturdy mounting point might make the lights bounce up and down like crazy. Just another idea, what about installing a third radiator hole on the bumper cover and mounting the light bar behind the radiator using the mounting tabs for the third radiator? Or cutting round holes into your bumper cover and mount the oval lights farther back and flush with the cover?
If you're set on mounting lights in front of the bumper, I would suggest mounting the light support bar either to the radiator support brackets or where the radiator brackets attach to the body

All super valid concerns, but I am dead set on the classic circular lights. Totally different aesthetic than light bars. The circular lights pay homage to Porsche's rally roots and give a nod to cannonball.

The absolute easiest way to accomplish this would hands down be to use the RTS system mounting points on the A pillar, but again aesthetic.

I'm also dead set on having the completely returnable to stock form, so cutting anything is out. Though I could see how cutting the lights IN to the bumper might actually look very good.

Last, I want to create a mount 'system'. Where I can swap lights for camera mounting, or a jerrycan carrier, or something else quickly and easily. I also want the system to be detachable due to theft (serious problem, my truck was stolen and stripped of its lights and offroad stuff)

I approach these things from a productionization point of view as well. If I'm going to invest 100+ hours in research and $1000+ in CNC tube bending/maching for a prototype. If there is demand, I might make a kit available publicly to try to amortize those costs.

Originally Posted by 1PorscheBoxster986

This is another interesting project you're taking head on beater. I think it's time to rename your Porsche Boxster to Porsche Campster. I look forward to another thread when you add a grill to the trunk. It's already a warming tray by itself after a nice drive.

Ha. You're reading my mind. I have some ideas for a concealable hitch system where a luggage rack (or other) can be mounted at the back.

[beater986]

Just ordered a space bumper bar to take measurements from.

Here's what I'm thinking for the mounting system:

[Starter986]

Beater...

Have you considered that bar you're designing... upon which you'll mount the lights... fabricating it in a manner so that it "plugs in", if you will, to the tow hook threads. That would be the only mounting point... and the part that screws into the tow hook bolt hole, the piece that will be mated to the bar... that mounting point (weld, bolts, nuts, whatever fastener) could be hidden or nicely finished.

No?

[beater986]

Originally Posted by Starter986

Beater...

Have you considered that bar you're designing... upon which you'll mount the lights... fabricating it in a manner so that it "plugs in", if you will, to the tow hook threads. That would be the only mounting point... and the part that screws into the tow hook bolt hole, the piece that will be mated to the bar... that mounting point (weld, bolts, nuts, whatever fastener) could be hidden or nicely finished.

No?

The only problem is I can't stop things from rotating, and having all of that mass of the bar relying on a single point is going to cause bounce.

The goal is still to have the bar removable in < 3 minutes back to stock so it can be thrown on quickly for excursions.

Here's progress:









Light spacing measurements are a bit off, but things are going well. Printing the (hopefully) last version now.

[Starter986]

That is looking awesome, Beater.

I'm impressed by the fabrication.