Rear bumper flush mount lights

BlueOx · Oct 29, 2013

Ok I'm wanting to install some 2x2 flush mount lights in my rear bumper. Anybody have any tips or tricks for cutting the holes in the bumper? I wanna make sure I do this right the first time lol

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12stroker · Oct 29, 2013

plasma cutter lol

Powerstroked162 · Oct 29, 2013

Dzchey21 did this on his truck. Came out looking awesome. Maybe he will chime in

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BlueOx · Oct 29, 2013

Powerstroked162 said:
Dzchey21 did this on his truck. Came out looking awesome. Maybe he will chime in

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I hope so! I just want to make sure I don't mess anything up. I know to double and triple check my measurements and all. I'm more worried about the cutting part

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BlueOx · Oct 29, 2013

12stroker said:
plasma cutter lol

Negative

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12stroker · Oct 29, 2013

use a cutting wheel.

BlueOx · Oct 29, 2013

12stroker said:
use a cutting wheel.

I considered that, but the only thing I have access to right now is a 4in grinder with a metabo wheel

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Powerstroked162 · Oct 29, 2013

12stroker said:
use a cutting wheel.

Yikes!

I'd suggest tracing your cut onto the bumper. Find the biggest hole-saw you can that will remove as much of the material as possible without exceeding your pattern. Then go in with a die grinder and a good single cut carbide tip and hog out the rest of the material in the corner. You could probably square up the corners off the hole-saw cut with a sawzall too. Hit it with a buffing wheel or a good rasp, light sand with emery cloth and bam, all done.

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12stroker · Oct 29, 2013

I know a guy that did his rigids like that and it came out great. And I am talking about a air cutting wheel which is the same as a die grinder.

Powerstroked162 · Oct 29, 2013

Still a 4" wheel though, right? I'd be worried about the corner junctions. You almost always have to make a pass further then your marks to remove any amount of material in a pattern, worth cutting out. I'm too anal for that lol

A super easy way to do it if you don't have the tools or access to them, would be to just take your bumper to a machine shop and have it water jetted out. Most places with a table are reasonable. Setup is usually the money consumer

12stroker · Oct 29, 2013

another member on here said he Grabbed a cheapo 3" electric cutoff tool at Harbor Freight. Used my dremel to smooth out the edges and hit the hole with some undercoating.

Powerstroked162 · Oct 29, 2013

Looks good! The light bezel probably works in favor of the guy cutting. You know what I'm saying about the wheels marks though. PITA

jdgleason · Oct 30, 2013

Those are kinda sweet!

I'd definitely use a sawz all.

LOL

BlueOx · Oct 30, 2013

jdgleason said:
Those are kinda sweet!

I'd definitely use a sawz all.

LOL

Lmao!!! I don't think I'll be putting a sawzall anywhere near my truck

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BlueOx · Oct 30, 2013

I'm just concerned with how hard the bumper material is. And wouldn't it being a chrome bumper make it even harder?

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12stroker · Oct 30, 2013

BlueOx said:
Lmao!!! I don't think I'll be putting a sawzall anywhere near my truck

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You already did to trim your bumper to fit those 37's LOL

jdgleason · Oct 30, 2013

BlueOx said:
Lmao!!! I don't think I'll be putting a sawzall anywhere near my truck

Sent from the wild blue yonder....

Lol

BlueOx · Oct 30, 2013

12stroker said:
You already did to trim your bumper to fit those 37's LOL

That wasn't done be me though. I didn't have the balls to do it myself lmao!

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sagebel · Oct 30, 2013

I used a cheap 3" cutoff tool from HF. I used Bean LED flushmounts and they needed a hole just over 3" square so it worked well. I have a painted bumper so I taped everything so I could mark the holes. I placed mine just inside the outer backup sensor. Make sure the hole clears the wiring if you have the backup sensors. I placed my holes 2" inside the sensor and that is about as close as you can get. Once I had the hole for the lights cut and test fitted I used a self-centering drill bit to mark the holes and then finished them with a 1/4" bit. Found some stainless 1/4-20 button head capscrews at Lowes to mount them with. Hit the edges with some undercoating or paint to seal the bare metal before you install the lights.