I decided to flush mount LED's in my fender flares for an extra turn signal. This was performed on a 2005 CRD sport.
The video below shows the final result with the hazard lights on. Please note, the video makes it seem as though they're white LEDs. I assure you, they are yellow and much brighter in person.
http://www.youtube.com/watch?v=XVDwGfj7viI
Tools and supplies:
Drill
1/4 inch bit
1/16 inch bit
Ruler
Center punch
Nylon pry bars
Exacto knife
Hot glue gun
Plastic rivet gun
8x 6.3X15mm pom rivets
2x Flexible LED Strips http://www.amazon.com/gp/product/B002SG1NUU
3 feet of speaker wire
4x wire tap-in connectors http://www.radioshack.com/product/index ... id=prod_cs
I started by removing the flares on the top side. There are 10 plastic plugs that keep it in place. Use one nylon pry bar to spread, and another to hit the sides of the plugs. They should come out no problem. There are 4 pom rivets on the bottom that also need to be removed. I used some side cutters and had no problems. There's also a clip near the front of the flares that hold it to the plastic wheel wells. Keep that in mind before tearing them off too fast.
This is what they look like removed:
This is how I pryed them off (you can see a plug to the left of the pry bar):
This is what the jeep looks like with it removed:
Next you need to mark the flare on the inside. There are 9 LEDs and they're spaced 1cm apart. I placed my first LED 5cm from the bottom. The whole strip is 1cm from the crease, but you can put them anywhere.
Marked:
After this, I center punched each mark and drilled 1/16 inch holes. I then drilled them out to 1/4 inch each. I used an exacto knife to clean up the final holes:
The LED strips are flexible enough that the holes don't have to be perfect. I put them in place and hot glued the crap out of them:
This is what they look like finished:
The wires were just a hair short to reach the turn signal harness. I used some cheap speaker wire to extend them about a foot. Use the wire tap-in connectors to attach the positive and negative. You could connect the negative to a grounded spot, but the harness seemed closer than anything else. Connect the negative to the black wire, and the positive to the red wire. You can disregard the white wire on the harness as it's used to run the park lights. I didn't have to use any resistors, it all matched up quite nicely.
Put everything back together and remember to attach all the plugs and the little clip thing. Attach all 4 pom rivets on the bottom side. I found it easier to turn the wheels while riveting to have enough clearance for the gun.
Here's what it looks like put together:
