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LED Tail Lights On A Chevy Blazer - Do-It-Yourself Custom Tails

Flush-Mounted LED Install
From the May, 2005 issue of Mini Truckin'
By Doug Millard
Photography by Courtesy of SIC
Led Tail Lights Installed On A Chevy Blazer Chevy Blazer
Led Tail Lights Installed On A Chevy Blazer Led Kits
1. Here's a look at the Custom... 
   
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Led Tail Lights Installed On A Chevy Blazer Led Kits
1. Here's a look at the Custom Classic Flush-Mount LED Kits. Each kit comes complete with an acrylic lens, a diffuser lens, the built LED unit (built as long as 42 inches), and all necessary wiring for a fully functional taillight system. Materials not included for the install are two-part-clear marine-grade epoxy, clear silicone, four small flathead machine screws, lock washers, and nuts.
Led Tail Lights Installed On A Chevy Blazer Tailgate
2. First off, decide on placement.... 
   
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Led Tail Lights Installed On A Chevy Blazer Tailgate
2. First off, decide on placement. We opted to put this set in the tailgate of a first-generation Chevy Blazer. Be sure that wherever you put them, you have ample room to access the light assembly from behind.
Led Tail Lights Installed On A Chevy Blazer Measure
3. We measured in from the... 
   
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Led Tail Lights Installed On A Chevy Blazer Measure
3. We measured in from the outside of the tailgate and marked our end point, then did the same from the top.
Led Tail Lights Installed On A Chevy Blazer Chevy Tailgate
4. Next, mark where you'll... 
   
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Led Tail Lights Installed On A Chevy Blazer Chevy Tailgate
4. Next, mark where you'll make your cut. The visible portion of the lens is 1/2 inch, so a piece of 1/2-inch masking tape cut to length works well and gives you a good idea of what the final product will look like.
Led Tail Lights Installed On A Chevy Blazer Cutoff Wheel
5. With a cutoff wheel, slowly... 
   
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Led Tail Lights Installed On A Chevy Blazer Cutoff Wheel
5. With a cutoff wheel, slowly cut out the marked portion of the tailgate. Be careful and take your time with this, as you don't want to have to fix any mistakes later on.
Led Tail Lights Installed On A Chevy Blazer Rotary Tool
6. Once the hole has been... 
   
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Led Tail Lights Installed On A Chevy Blazer Rotary Tool
6. Once the hole has been cut and you've test-fit the lens, you'll need to get the rear of the panel ready for installation of the bucket. First, prep the area for welding. If it's a tight space, such as in the Blazer, a rotary tool and flapper wheel work great for removing paint and undercoating. A section of the tailgate may also need to be cut out for better access to the LED mounting area.
Led Tail Lights Installed On A Chevy Blazer Mounting Spots
7. Using the LED bucket as... 
   
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Led Tail Lights Installed On A Chevy Blazer Mounting Spots
7. Using the LED bucket as a template, set the position of your light and mark the mounting spots for your screws. The screws will serve to mount the LED buckets in place, so in the event that a light does go out, you can remove the bucket and replace it.
Led Tail Lights Installed On A Chevy Blazer Screws
8. Place the flathead screws... 
   
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Led Tail Lights Installed On A Chevy Blazer Screws
8. Place the flathead screws on the marked spots and tack-weld them to the tailgate, making sure not to overdo it and warp anything.
Led Tail Lights Installed On A Chevy Blazer Epoxy
9. After test-fitting the... 
   
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Led Tail Lights Installed On A Chevy Blazer Epoxy
9. After test-fitting the bucket, it was time to set in the lens assembly. First, get out your two-part epoxy and mix it per the manufacturer's specifications.

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