So I just finished installing a Randy Ellis Designs light bar and two pair of Hellas (500ff and 700ff driving lights) on my 2004 FX4 screw. I fabbed up a custom switch panel in the cubby beneath the pull out cupholder in the dash and installed some aircraft style safety toggles. Here are the build photos and some brief captions:
Here is the "Pre" photo. As you can see, the previous owner installed two PIAA fogs in the gap in the bumper.
I chose the Randy Ellis Designs light bar because I liked the 1-3/4" tubing and it also happened to mount in between the existing PIAA fogs without alteration.
Painted the hardware for the Hellas.
The wiring under the hood is pretty basic so I will skip that. I mounted the relays near the firewall on the passenger side in case you are wondering. So, now, here is the switch panel which I am quite proud of. I started by removing the empty (and useless might I add) cubby beneath the pull out cupholder. I slotted the top of it with a dremel to make room for a piece of 1/8" ABS textured plastic which would make the front of my switch panel. I also cut a large portion out of the top in order to install the switches from the back.
Next I cut out the ABS face plate using a paper template and slid it in through the top, trimming to fit.
Next, I drilled the holes for the switches, and test fitted the switches. When I was comfortable with the fit, I made some gussets and used a plastic epoxy to tie everything together.
Finally, I wired the relay leads to the switches and then from the switch to an empty port on the fuse box which only operates when the ignition is on (no dead battery if the lights are left on without the key in). I tied the existing PIAA fogs into the switch panel as well. So, three of the switches are used: PIAA 510 fogs, Hella 500ff's, and Hella 700ff's (one dummy switch for future use just because I felt like it). I am super happy with it, it looks pretty professional and is not too obnoxious like some of the bright LED switches out there.
You all know how hard it is to do lights justice in a picture but here it is anyway...