cutting through chrome bumper??

[aldive]

I remembered seeing in an Explorer Express catalog a picture of an Explorer they "tricked out" and it had backup lights mounted in the bumper.

I wrote and asked them how they did it. They said theu were carefully cut with hole saw.

 

[Campo]

Here's what you do,

drill a 1/8" hole and get a step drill bit.. you can buy them in sets of 3-4 for $50 or get one for about $12-$15 depending on size that fit a 3/8" drill. the other's I've used go up to 3" -4 " but you have to use a 1/2" hammer drill.. and there more expensive like $25 - $50 apiece... but they make nice clean holes...

you can get them at sears and other hardware stores.. for the bigger ones you may have to find a MAC or snapon dealer...

here's a pic of a set that goes up to 3/4"...

 

[mikeh]

I would not do this because of the fear of developing a nasty rattle. However if you insist.

1. Draw a circle where you want the hole with a magic marker.

2. Drill a hole with a metal drill bit 1/8" hole near the edge of the circle (on the inside of the circle).

3. Drill with a larger bit so that you can put in your jig saw blade.

4. Use a jigsaw with the finest metal cutting teeth you can find. (The teeth are very small and close together). Jigsaw our the hole.

5. Take a round file and smooth out the hole so that you get rid of the sharp edge.

6. Reroute the muffler.

7. Buy a new bumper and reroute the muffler when you get sick of hearing the rattle .

Mike H.

 

[aldive]

If you attempt this with a jig saw, you had better be pretty good with the saw or the hole will not be round.

 

[rustytr]

I'm still trying to picture what it's gonna look like, more of if it will look good or not.

 

[X24]

I know what piece you are talking about. That piece is not very thick so it probably will not be very hard to do. you are talking about the piece that is on the passengers side between the rear wheel well and the bumber, right? I'm not sure how good it will look but if you get it done post some pics.

 

[aldive]

Originally posted by 98FordX24
I know what piece you are talking about. That piece is not very thick so it probably will not be very hard to do. you are talking about the piece that is on the passengers side between the rear wheel well and the bumber, right? I'm not sure how good it will look but if you get it done post some pics.

On my 99, that's plastic. Should be a snap to drill.

 

[EliteConcept]

thanks for you help guys

i talked to a body shop guy today, and he said he wouldn't advise it.....details about the coating on the chrome pealing....

i don't think i'll be doing this now.


later,
ryan

 

[Hartman]

Another thing to think about is that the Explorers have high rear bumpers. In order for the pipe to go through the bumper, it would be pretty high and wouldn't look that great.

 

[beavis195]

Not 100% sure, but I think for The Stillen Ground Effects for 91-94 X's, the exhaust pipe exits through that piece. Check Physkotone's (spelling?) X on this site. He has it. I'll look for it now.

 

[explorersvt]

Sorry to say but pretty much all of these ideas could potentially do more damage than good. I did the very thing you want to do and i used a plasma cutting torch set at forty amps. I used some black ruber gromet material to trim it out and it looks sweet. You will get a slight discoloration around the hole about 1/16 to 3/32, that is another reason i used the trim piece. If you need any help e-mail me at mkejmorgan@hotmail.com. Here are some pics.
http://www.sounddomain.com/member_p...ery=model=Explorer&tree=Ford Explorer:bounce:

 

[explorersvt]

Sorry to say but pretty much all of these ideas could potentially do more damage than good. I did the very thing you want to do and i used a plasma cutting torch set at forty amps. I used some black ruber gromet material to trim it out and it looks sweet. You will get a slight discoloration around the hole about 1/16 to 3/32, that is another reason i used the trim piece. If you need any help e-mail me at mkejmorgan@hotmail.com. Here are some pics.
http://www.sounddomain.com/member_p...brand_query=model=Explorer&tree=Ford Explorer

 

[ok89]

From what I understand you want to exit through the plastic area between the wheel well and the bumper right? That shouldn't be that hard to do.