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Cutting Rear Bumper. Please help

Discussion in 'Chevy Trucks' started by coachglynn, Sep 26, 2005.

  1. coachglynn

    coachglynn Junior Member
    Messages: 29

    Hey guys, you are the best source for info. I am trying to install a couple strobe heads in my rear bumper. I want to flush mount them so they don't stick out. I already have the lights and stuff, I was just wondering what you guys would suggest to cut the rectangle hole in the rear bumper. My options are a cutting wheel, or taking it to a body shop to have it cut. I was hoping to do it myself. Thanks in advance for any input.

  2. wfd44

    wfd44 Senior Member
    from Maine
    Messages: 369

    Body shop and a plasma cutter would get my vote.
  3. wls

    wls Senior Member
    Messages: 319

    My son-in-law used my regular old gas torches.

    In the second pic, there's a light in the right lower corner, in the bumper

    salter lights 001.jpg

    salter lights 003.jpg
  4. wls

    wls Senior Member
    Messages: 319

    Heres the drivers side.

    salter lights 002.jpg
  5. KeeblerBP

    KeeblerBP Member
    Messages: 35

    When I cut the holes in my rear bumper for extra backup lights we used a holesaw for each end and a Reciprocating saw to connect the holes for the lights. The lights I installed were oval (like many trailer lights).

    This worked great for my truck that has a chrome bumper. We tried the same thing on my friends truck that has a stainless steel bumper that is much harder than the steel/chrome bumper mine has. We were using cheap blades and hole saws, but the hole saws would only make one hole each before the teeth were gone. The dewalt blades were only making a cut for about 2" before they were junk.

    Good luck!

  6. Robhollar

    Robhollar Senior Member
    Messages: 766

    You just reminded me why I love my plasma cutter so much.....Rob
  7. coachglynn

    coachglynn Junior Member
    Messages: 29

    Thanks for the responses. I ended up drilling 1/2" holes then cutting with a jigsaw. Went pretty smooth.
  8. lorentzlawnsnow

    lorentzlawnsnow Senior Member
    Messages: 143

    stainless steel becomes work hardened when you try to machine it outside of very strict annealing cycles. this is why you had so much trouble with it. you almost have to be a metallurgist to work the stuff. the equipment you were using to make your cuts was designed for mild steel like the chrome bumper was made out of which does not have the work hardening characteristics caused by machining.
  9. MickiRig1

    MickiRig1 PlowSite Veteran
    Messages: 3,617

    Four words: Air Cut Off Tool
    It's one of my best toys!
    Then my second best toy: Drimal to clean up the edges!