Hey everybody I'm hoping somebody can help me with the latest project I've got in the works. I've finally gotten my bumper & had two sets of PIAA driving lights, 510's & 520's. I had originally planned on putting the 520's behind the grill, but it didn't work so well with my new grill. I had already given the 510's to my husband for his jeep. So I have the 520's to work with. What I really need some with is modifying the bumper holes to fit the 520's. I don't have access to a plasma cutter, unfortunately. I do have assorted grinders, dremel, drills & a jig saw.
I obviously want it to look as professional as possible & keep my rock guards if possible. I thought I could have the local machine shop fabricate a bezel or something to hide any rough edges if needed.
So what do you guys think would be the best way to cut the bumper & hide any rough edges? I also will probably need to fabricate mounting bracketry.
Any ideas are only going to help me. I really appreciate any help on this. Sorry for the craptacular photo's, had a dog in my face.
Thanks!!
Rhonda

 

get dimensions of fog light, get a piece of chalk and mark out what needs to be trimmed off and take it to a welder. angle grind the edges yourself

 

Find a lid to a large can,i.e coffee or Crisco etc that is 6.5 inches diameter. Center it to the hole you already have and draw outline. This will give 1/4"gap completely around light. Once centered have a piece of flat stock shaped with a step down from your mount hole on bumper to the location of your light mount. That is basically how they are on my truck. My truck has a PIAA air dam with 520's if want to look at for reference.

 

Ok thanks guys! we'll see how this turns out.
Rhonda