While getting a TRM LED light kit ready to ship out to a forum member, I decided today would be the perfect time to drill out the holes for the LED lamps.
I've done several of these and have discovered a couple of things that help get the job done easily. After the build off crunch is over I need to create another instruction sheet with these tips.
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Drilling a 3/4" hole is first. There is a center mark in each light location on the tank. A step drill is the absolute best way to drill the holes. They can be purchased from
Harbor Freight for fairly cheap and you'll wonder how you ever got by without one if you don't use them already!
I have found that just pushing through without checking along the way can result in the hole being off center. Because the fiberglass is hand layed it can vary in thickness especially down inside the small headlight cavity. If the glass is thicker on one side it can cause the drill to travel to the thinner side that has less resistance. I drill each step on the bit and check to see if it needs to be pushed one way or another as I go.
Once the holes are drilled it's time to prepare the holes for the rubber grommets. It will work to just push them in at this point but they will hold better if the inside rim is relieved to accept the back lip of the grommet. The best way that I found to do this is with a rotary tool. You can also do it with an inexpensive small grinding rock and a drill. The fiberglass is very easy to grind away so go slowly. I try to match the thickness of the tank opening to the thickness of the slot in the rubber. It's pretty forgiving so it doesn't have to be perfect all the way around.
Check the thicness of the rim and slot.
Finally the grommet is pushed into place.
It's now ready for the LED light which is pushed into the grommet. DONE!
I forgot to put the chrome bezel on it for the photo but you get the idea.
Tic toc tic toc
