Need to drill 4" holes in stock bumper - how?
 

OK... silly question. I'd like to put auxiliary backup LED lights in my stock chrome bumper to add light at night when backing, closing gates, hooking / unhooking trailers, loading bikes, etc.

But what is the best / easiest way to drill a 4" hole into the bumper so I can install the lights?

I want them flush or sunken so as to limit damage.

TIA,
CORed

If you have one of those dremel tools, they are great for stuff like that. If not you could drill a pilot hole and use a jig saw, if the lights your using have the rubber grommets around them they will hide some of the imperfections if your off a little

I just did this mod and used my factory driving lights in the holes , tricky job lost of measureing and I used a jig saw . Ya have to cut the grommets and remelt them back together to fit the lights. I'll try and post a pic.

What would be wrong with using a hole saw? You know.....the kind that goes in a drill? They make them for metal.

Might work but bumper is not flat and I think it would bite a little , plus in my case the hole had to be just the right size and was not near any of my hole saw sizes.

Heres a pic not a close up though.

It takes a steady hand, but I have done it before. Front bumper and grill guard I installed for a customer had to have a couple of 2" holes in the bumper. Like I said.....slow and steady!

I would buy a good metal hole saw and just take it easy with it like VZ said.

two words that help a lot : weather stripping... makes up for not so perfect cuts, and gives the edge a nice finished look.

I used door edge guard from Walmart! Put the slit at the bottom, and it looked VERY slick! Cut it with tin snips.

Good metal hole saw... take it slow, but not too slow to where it is real grabby.. should be easy enough

I use norseman drill bits with lennox holesaws. Predrill the 1/4" hole and like the others said take it slow.

So a metal 4" hole saw seems to be the recommendation after drilling a pilot hole. Awesome... thanks guys.

BTW, the standard 4" lights that squeeze into the rubber grommet... are they just UNDER 4" so they fit into a 4" hole cut by a hole saw?

Thanks much! I'll be looking for a 4" hole saw soon.

CORed

Be prepared:
A quality 4" hole saw is not cheap. Add more if you have to get an arbor.

If you pre-drill the 1/4" center I prefer using 1/4" stock in the arbor. On an uneven surface a drill in the arbor can easily oblong the pilot hole.

HOly s%$#@....I think you need to change your user name to "top heavy." No high speed turns for you.

whats the rating on that alum bed mount?.....pretty cool!