winch bumper - recessed lights

[Redd]

Guys hey.

Might as well start by saying this isnt for a toyota, I was a longtime member of this forum however and I'm hoping someone will have some tips or links as to how to build these recessed light fixtures

I'm wondering did they use steel pipe of the same diameter as the lights.... or how exactly to go about it.

It's for this truck, its a bremach t-trek

here is the bumper so far

 

[firestopper]

Redd, I would use round tubing or pipe to for this application. If you know the diameter of the light you will be using that would be a great start in researching the ID of material you'll need. I would probably go with 1/2" or 3/4" larger so when the lights are pointed straight they won't be too crowded and present with a nice revival. Once you find your "sleeve" tac it in place, trace around the the outside of the bumper for you contour cut.
I would work out all the light mounting brackets prior to welding the sleeve in so all of the welding will be done from the face of the bumper. Recess the sleeve so when you grind it smooth you still have a strong weld joint. I hope I made sense to you.

Many way to skin a cat, but this is how I would tackle it.

Keep us posted on your progress

 

[Redd]

cheers Firestopper, makes a lot of sense. Will post updates, regards )

 

[PAToyota]

What Firestopper said. You’re basically “frenching” the lights into the bumper. If you search, you’ll see the old hot rodders were using exhaust pipe to “french” lights and other things into the sheetmetal. You’ll find pictures and articles that will illustrate things for you about how it is all done.

For the bumper, using pipe would be easier to weld as it would be closer to the thickness of the bumper. It’s easiest when you’re going straight into the surface because the hole in the surface will be a circle. If the surface is at an angle (like your first photo) then the hole is an oval and gets a bit more complex. Still not hard if the surface is relatively flat - but try doing it on a compound curve.