Best tool to open up fog light holes on 1996 850 bumper/valance, and any tips?

[slickdizzy]

Hi all,

For those unaware, 850s without factory fog lights have the outlines for the fog light holes on the inside of the bumper/valance so you can cut them out and install trim rings to add fog lights. I intend to do just that, but I'm wondering if anyone who has done the job before can comment on what they used to cut the holes and if they have any tips.

Going in blind, my plan was to use a hole saw to get as close as possible to the OD of the fog light cutouts, then use a Dremel with a 561 bit to get up to the edges. But if anyone else has done the job and knows of an easier/better way, I'm curious to hear it!

IMG_5253.jpg (105.07 KiB) Viewed 984 times

[scot850]

That is probably what exactly what I would do. Cut it out to as close as I can to the final diameter and then dress it back. The other option might be one of those drywall routers but it would depend on the bumper profile:

https://www.amazon.ca/DEWALT-DCS551B-Vo ... 1589&psc=1

This type of thing. Some guys call it a roto-zip.

Neil.

[BEJinFbk]

Stick with a Dremel bit. I prefer to use it with a cable.
I’ve also got a piece of heater hose on the handle of
the extension cable to provide a larger diameter to
reduce strain during extended use and a better grip.

[slickdizzy]

Just to close the loop on this, I ended up doing the job with a simple utility knife. The key is to use high quality blades and make many small cuts around the perimeter, going deeper and deeper each time. When you’re done, just hit the perimeter with some sandpaper to smooth out the cuts. It probably took me about 45 minutes to do both sides.

[SonicAdventure]

Shoot, I missed this. I did this about two years ago. It was a pain. I put blue painters tape over the exterior of the corners, and from the inside I used a cordless soldering iron and poked through the ring outlines from along the inner of the two, I believe. I then finished it with a cheap cordless “dremel” from Harbor Freight, combination of sand drums and stones.

I found it to be way harder than it’s worth; unlike the fogs the V and S series came with, these round ones are so dim you can barely notice them when they are on. I would not put myself through the trouble a second time.

Is there an aftermarket LED bulb for these old lamp that will amp up the brightness? I know my bulbs work they just don’t put out much light at all.

[slickdizzy]

Shoot, I missed this. I did this about two years ago. It was a pain. I put blue painters tape over the exterior of the corners, and from the inside I used a cordless soldering iron and poked through the ring outlines from along the inner of the two, I believe. I then finished it with a cheap cordless “dremel” from Harbor Freight, combination of sand drums and stones.

I found it to be way harder than it’s worth; unlike the fogs the V and S series came with, these round ones are so dim you can barely notice them when they are on. I would not put myself through the trouble a second time.

Is there an aftermarket LED bulb for these old lamp that will amp up the brightness? I know my bulbs work they just don’t put out much light at all.

Strange, I had the factory fogs on a prior 850R and found them adequate.

Yes, there are many aftermarket bulb options, LED and non, though the way that bulbs are installed on the 850 fogs precludes the use of some of the really hardcore LED options.