Need to cut a 4.5 inch hole in my rear bumper. Any suggestions?

[Motorhead]

I want to mount a pair of auxiliary back up lights on my stock rear bumper. Need a 4. 5 inch hole. Any suggestions other than buying some real expensive hole saw?

 

[n7gxz]

What do you concider to be "real expensive"? Homedepot shows the price around $35 if you have a mandral already.

Kevin

 

[MarkEkberg]

I want to mount a pair of auxiliary back up lights on my stock rear bumper. Need a 4. 5 inch hole. Any suggestions other than buying some real expensive hole saw?

Jig saw will do it and the rubber will hide and imperfections.

 

[mwilson]

Do you have a buddy that is proficient with a plasma cutter???



That is how we did Seth's bumper. No discoloring shows, the rubber hides it.



Mike.

 

[PatrickMarshall]

Not to worry. You can use a jig saw. Tape over the area where you want to cut, mark it out, drill a pilot hole and fire up the jig saw. These bumpers are not that thick, a good metal blade will make it like cutting through butter.

But first you need to get a couple of the rubber light gaskets/holders and cut them to fit your lights, then measure the size hole you need. I had a couple of fog lights on the shelf from a 99 Ram and used those. Also you might want to think about installing a three way switch so they can be used as aux. backup lights or just for light by themselves. Sure makes it nice when it's dark!

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[jelag]

I used the standard rubber grommet for a 4" round lens... and mounted a 4" 35 watt flood light used on some tractor lighting... Lots of light...

 

[Motorhead]

Patrick, That's nice! That is what I am after. LED lamps? That is what I am using

 

[seafish]

Motorhead, Par36 bulbs are available in many different spreads and wattages, and they ALL fit into the 4" rubber grommets.

I used these 50w halogen in a wide flood pattren and they light up behind my truck like headlights, yet still have a 5000 hour life (not really important, given the frequncy of use, but still much better then the landing lights some people use which last for 25 hours).

http://www.elightbulbs.com/Halco-107786-HP36WFL50-HX-PAR36-Halogen-Light-Bulb

I found out the hard way to use the rubber grommets that have a full pocket for the bulb , not just a mounting ring. I had several bulbs crack from gravel/rocks sprayed up from the tire, befoer I switched to these grommets--

http://www.grote.com/product.php?product_number=91950

Tape and fine tooth metal jig saw will work fine, then seal the edges of the cut to help prevent rust.

Also, DO wire them in with a 3 way switchlike other have said so that you can use them for work lights when needed>

 

[Allnew2Me]

Here is a thread I posted in 2006 that tells how I did what you describe.



https://www.turbodieselregister.com...be-light!-In-reverse!&highlight=light+reverse

 

[RCMerrill]

Do you know any Electricians they have Knock outs up to 6" put a 1" hole in bumper insert knock out through hole & tighten down. it makes a nice hole.