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

Old 02-18-2008, 04:04 PM
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Question 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,
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Old 02-18-2008, 04:44 PM
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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
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Old 02-18-2008, 05:00 PM
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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.
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Old 02-18-2008, 05:05 PM
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What would be wrong with using a hole saw? You know.....the kind that goes in a drill? They make them for metal.
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Old 02-18-2008, 05:10 PM
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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.
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Old 02-18-2008, 05:11 PM
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Heres a pic not a close up though.
Attached Thumbnails Need to drill 4" holes in stock bumper - how?-%7E3023474.jpg  
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Old 02-18-2008, 05:13 PM
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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!
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Old 02-18-2008, 05:20 PM
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I would buy a good metal hole saw and just take it easy with it like VZ said.
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Old 02-18-2008, 05:32 PM
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two words that help a lot : weather stripping... makes up for not so perfect cuts, and gives the edge a nice finished look.
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Old 02-18-2008, 06:31 PM
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I used door edge guard from Walmart! Put the slit at the bottom, and it looked VERY slick! Cut it with tin snips.
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Old 02-18-2008, 06:43 PM
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Good metal hole saw... take it slow, but not too slow to where it is real grabby.. should be easy enough
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Old 02-18-2008, 07:13 PM
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I use norseman drill bits with lennox holesaws. Predrill the 1/4" hole and like the others said take it slow.
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Old 02-18-2008, 07:36 PM
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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.

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Old 02-18-2008, 09:33 PM
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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.
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Old 02-19-2008, 07:51 AM
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Originally Posted by caper View Post
Heres a pic not a close up though.
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!
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