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OEM Monarch light array removed. | The remain of the old Monarch Fixture. | Two PVC panels were cut by TAP. I then taped them so I could mark with a Sharpie and cut without marring the PVC. | In the mean time, I cut oak strips to add thickness to the inside of the FMC cutout. Then sealed them with Varathane. |
Inside looking out. Note: the old spacer pieces of rotten plywood were chiseled out. | I also lined the fiberglass opening with tape so the tracings of the Sharpie would not discolor the gel coat. | With the outlines drawn in place, I started locating the lenses. | Cutouts were tedious. Very fine sabre saw blade, very slowly, otherwise the PVC re-welds itself together. Screw mount flanges were cut with a Dremel fine rotary. |
Cut outs were lined with Scotch 90% reflectance tape, ICC standard. | Full final assembly. | Mounted with #8 bolts going through the Truck-Lite reflectors, the fiberglass, the oak spacers and finally the PVC board. | Yep. One side is definately brighter than the other. Even the 2nd lamp working on the left wouldn't make it. The reflectors I can see from way off. |
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