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Remove the old stuff
Start by removing
the factory plastic skid plate then bumper
followed by the plastic closeout on top of the
frame. TIP: Be sure to disconnect
the fog lights and detach the wiring harness
from the inside of the bumper.
TIP:
Removing the plastic "scrivet" fasteners can be
very difficult. Honestly they can be near
impossible. We used a thin flat chisel and
hammer to cut them off since they will not be
reused.
With the bumper
removed remove the fog lights from the back of
the stock bumper and install them in the new
brackets.
Fog Light
Wiring Modification
In the directions
it is indicated how to modify the fog light
wiring harness since the lights are placed
outside the frame rails on the AEV bumper.
The directions state not to cut the wires but we
could not make it work so we needed to cut and
lengthen the drivers side.
If you decide you
need to lengthen the wiring be sure to use
quality connectors and proper gauge wire.
We used a new piece of wiremold on the extension
all the way to the light.
Frame
Preparation
There are several
holes that need to be enlarged to accommodate
the larger bolts. For some reason it is
even necessary to enlarge holes on the AEV
supplied components, why?
Time for some
cutting
Remove the inner
steel bumper from the outer plastic shell.
Since the AEV bumper uses the factory crush cans
they must be cut out from the factory bumper.
The cleanest and easiest method is to use a cut
off wheel in an angle grinder. Carefully
cut out the cans making sure to leave plenty of
extra material.
After cutting out
both cans use the supplied template to trace a
pattern on the back of the cans. Trim the
cans to match the template. We used the
cut off wheel, bench grinder, and die grinder to
obtain the proper shape.
Next Page - Installation
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TIP:
Be sure
to apply paint or rust inhibitor to
all drilled out or exposed metal
surfaces.
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Instructions
Inconsistency ??
In the directions it indicates precise
cutting of the crush can to obtain a proper fit
but the above image from the AEV instructions
shows the cans not trimmed and drilled to be
bolted in using the can cover bolts. You
decide which method to use.
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