Installing aux lights on front bumper

SavageUrge · **Posted:** Sun May 27, 2007 3:56 am

I know there was a write-up a while back on how some of you guys installed Piaa or Hella lights on the front bumper. As usual, the search function is useless, and I looked in the "How-To" section to no avail. Could someone point me in the right direction? have the wires all run, I just need to find out how you found the mounting holes and went about measuring/drilling. Thanks!

LostRenegade · **Posted:** Sun May 27, 2007 8:55 am

Underneath the front tow hooks is an access hole where you can drill up to make the mounting hole for the lights. You will need to take the bumper cover and tow hooks off to drill your holes. Put bumper cover back on but only fasten it around the top. The bottom needs to stay open for now. Once cover is on and fastened around the top, drill holes through cover. Mount the lights. Re-install tow hooks. Fasten bottom of bumper cover.

SavageUrge · **Posted:** Sun May 27, 2007 7:09 pm

Sounds easy enough, thanks! If anyone has pics of this it would be great. I see some square holes underneath, so it would be necessary to remove the bumper cover, however it doesn't look like I need to remove my tow hooks. Maybe we are talking about two separate sets of holes?

LostRenegade · **Posted:** Sun May 27, 2007 10:26 pm

It must be a different set of holes then. The tow hood bracket covers the hole that I was talking about.

The tedious part is putting everything back together. The bumper cover has to go back on when you go to install the lights. Getting to the nut for the lights and the bolts for the tow hooks with the bumper cover on can be a bit of a pain.

I did it twice on mine. Once to put the lights on, and then again to replace the tow hooks with a front hitch.

corwyyn · **Posted:** Mon May 28, 2007 12:30 am

Here's a couple of pics to help locate where to drill. The first one has some measurements that work on all the older ('02-'04) front bumpers. I mounted mine 3/4" out from the grille and can get them aimed but they do touch which is why I show the measurement as 1":

And yes it is 3 1/2", the angle of the image makes it look less than that.

And here is one of the underside showing the opening to access the bolts once you mount them - its the rounded rectangular opening just inboard of the hitch mounting point.

You can drill right thru the plastic cover without removing it, just be sure to add some silicone sealant to help keep water off of the unpainted metal edges. A long extension and socket from underneath will get the nuts onto the bolts and help to get everything tightened up. Good luck with the install and be sure to post some 'after' pics

Oh, and I just took a look at the installation instructions for the tow hooks, and the two holes you'd need are right where the tow hooks mount, so you'd need to remove them if you go this route.

SavageUrge · **Posted:** Mon May 28, 2007 4:19 am

Beauty! Those pics are excellent. The measurements are just what I needed. Not to be critical corwyyn, but the measurement that says 3.5" from the side of the light looks to be no more than 2". I will heed your advice to add 1" from the back of the light though. I believe my Piaa 520's are just a tad deeper than those Hellas. Thank you!

corwyyn · **Posted:** Mon May 28, 2007 1:47 pm

SavageUrge wrote:

Not to be critical corwyyn, but the measurement that says 3.5" from the side of the light looks to be no more than 2". I will heed your advice to add 1" from the back of the light though. I believe my Piaa 520's are just a tad deeper than those Hellas. Thank you!

Yeah, the angle I took that shot at doesn't help. so here is a straight-on shot:

I also checked the measurement from the grille while I was out there and on mine it's actually 3/4" from the grille, so I added 1/4" to the measurement already. You might try test fitting the PIAAs before you drill, I'm not sure you can go 2" and still have enough room to get the nut on the bolt inside the bumper. Unfortunately my front hitch gets in the way when I try to get a shot up inside so I can't post one for you.

SavageUrge · **Posted:** Mon May 28, 2007 7:34 pm

After wrestling with the darn bumper cover for what seemed like an eternity, I finally got one bracket mounted - yes, only one as I was afraid to run out of daylight while I was working on the other side. The clips that hold the wheel flare to the bumper cover are the WORST PITA's! Out of sheer frustration, I took a screwdriver and pushed the @$#% things out of their mounting slots, and just replaced them right before I put the bumper back on. ANYWAY...The measurements I used are 2-7/16 (center of hole to the framework behind the grill) and and 3-3/16 (center of hole to side of bumper). I don't think I'm going to attempt to put the tow hooks back on since I don't go off-road and it just looks like WAY too much of a PITA! Thanks again for you assistance corwyyn! As soon as I get the other side mounted, I'll post some pics with all my lights!

Katmandu · **Posted:** Sun Nov 15, 2009 7:40 pm

Man, you guys are great!

What needs to be done with the Bumper cover ?

Also, can someone confirm that this will work on an 2005 ??

SavageUrge · **Posted:** Mon Nov 16, 2009 1:12 am

So decided to mount the tow hooks again. Instead of fumbling with the bumper cover, I took the largest hole saw I had and just drilled a nice big hole in the bottom of the bumper cover! LOL It worked like a charm. I had plenty of room to work and the socket with a swivel got the job done. Hell, it's paid for :lol:

Now I have some additional "cooling vents" in the front

oddball · **Posted:** Mon Nov 16, 2009 8:02 pm

I too have used those pic's from corwyyn but thought I would add, a magnet can be a great aid to finding metal under plastic. I've used a 1" length x 1/2" thick cylinder shape magnet on the front bumper cover, rear bumper and many plastic / metal points in-between.

Katmandu · **Posted:** Mon Nov 23, 2009 11:14 am

SavageUrge wrote:

After wrestling with the darn bumper cover for what seemed like an eternity,......

I'll post some pics with all my lights!

How bout some more pics!

What needs to be done with the bumper cover ??????

Installing aux lights on front bumper

Who is online