Ive decided its gonna be cheaper for me to buy the stock round foglights and black plastic bezels and weld my rectangular openings to circular ones instead of trying to find a front bumper with round holes... since I do bodywork and paint. Can someone take pics or explain to me how the round fogs and bezels mount to the back of the bumper? Just need some ideas since I run a CNC mill at work so I can pretty much machine any custom parts i will need.

Ive even gone as far as going to local Ford dealerships and asking the bodyshop if they have any smashed or dented chrome bumpers since they trash them anyways.. no luck yet.

 

my truck will be at the body shop thru and friday and ill be sure to snap a whole lot of pics for you. Ill take measurements too but they are VERY simple to do. the plastic outer cover/mount simply bolts on to the bumper via three bolts, two on the top edge of the bumper and one on the bottom edge.
It would just be a matter of getting the complete fog assemblies and drilling the appropriate holes in the lip. then lining it up, marking the circle hole, and cutting it out and filling in the left over square area.
Also note, the round (more like oval) cutout for the fogs on the 06+ has the edges beveled in.

 

Actually found a bumper today... but it was smashed to hell so i had them use a cutting torch and cut me off the ends of the bumper. Ill be grafting in the new pieces next week. Gonna stop at the dealership and pick up as many parts as i can. Pics would be appreciated. Thanx

 

You really dont have to post pics... this is gonna be way easier than i thought. All i needed is the black housing and the actual foglight lenses. All I gotta do is bolt those two things up and then align and weld in the chunk I cut off of the round foglight donor bumper, slap some mud on it and base and clear it, and buff it. And since i can slide the foglights over in the bumper im gonna move them out so the fogs are in line with the headlights. Bada bing!

 

Due to the contour of the bumper you may not be able to move them further outboard, Also the fogs are pretty much designed for thier current location, moving them further outward would put more of an angle on them towards the outside and they would fire off the light to the front corners of the truck instead of straight ahead.
In order to move them outboard you would need to modify the light housings so that the centermost (to the truck) mount would sit a little further back, and you would need to either trim the black ring on one side or add to the other side depending on how you decide to mount them.
Just food for thought, although im sure you already thought of this.

 

I was planning on machining some shims to go behind them to aim the back towards center. Gotta get some 4x12 pieces of steel cut on monday to fill in the rectangular openings, then cut a hole for the circular fogs sections and weld them in. Hopefully I have it all done and repainted by next weekend.

 

Looks like you got it all thought out.
Post up some pics when your done.
Just wondering though your profile shows an 07 is this for another truck?

 

My truck was smashed before I bought it and thats the only bumper they had in the yard when they fixed it.

 

Oh hell, i would have made them to put the correct bumper on there man...
or at least pay to have the correct one on there....

 

I love doing bodywork, so i dont mind. Used to own a showcar that I had over $40,000 stuck into, did my own custom widebody, headlight and tailight conversions, one suicide door, one lambo door, was in the process of converting it to right hand drive but ended up selling the firewall i had shipped from japan to someone else. all kinds of crazy ****.

Im actually thinking about finding a smashed bed off a 2009 and grafting the tails onto my bed. That and doing a whole 09 front clip conversion... cheaper than buying a new truck

 

ha, thats kinda weird i was looking at a 09 yesterday that parked next to me, and despite what ford said the cab demensions looked EXACTLY like mine. as a matter of fact, from the front fender rear edge to the end of the cab it looked dead on like an 04-08 and the only thing really different were the upper wheel well body lines. i am almost willing to bet the front end will bolt on.
If you do tails, do the 08-09 expy tails... they look sooo good to me for some reason!

 

lets see some pictures

 

Finally got started last night... Welded in temporary filler plates so when I cut out the opening for the circular fogs the bumper stays rigid, Ill later be welding a continuous bead. Cut out and grinded the fog circles today, cutting out the circles holes in my bumper tomomorow after work, maybe welding the round parts in tommorow night. Filler and primer to come this weekend.

We also just got hit with 10+ inches of snow up here, lots of fun!

 

Didnt get to weld in my pieces... snowboarding comes first on the weekends! Got the rings all ground down and ready, then its self etching primer, filler, primer and paint.

Moved the foglights out about 5 inches so they line up with the headlights, im sure im the only one who's gonna notice but i love subtle changes to vehicles

 

some updates...