by bartonmd » Wed Jul 13, 2011 8:25 am
Wow, that looks way better on the computer screen than it did on my phone, even!
The light holes really turned out great, if I do say so myself! Cut a piece of pipe at the angle of the front of the bumper, trace it inside and outside on the front, plasma cut in between the lines (and clean up), put the pipe on from the rear, seam weld around the front, angle grind and die grind the weld and radius smooth, then 4.5" flap disk the big ones and rotary die grinder flap disk the small ones... One set of holes takes me ~2-3 hours to do, start to finish... IMO, frenching them in adds a little something to the "hole saw and roll a piece of sheet metal and tack it in behind" method...
Mike