Best way to cut a 4in hole for reverse light

[SquirrelCrusher]

I want/need reverse lights on my cherokee. I had some autozone specials mounted to my hitch before the bumper went on. Now I'm thinking a 4in utility LED like this - http://www.etrailer.com/tv-Demo-Optroni ... L43CB.aspx - would work pretty good. However, how do I cut a nice 4in hole in 3/16 steel? The bumper is already painted so I want to keep from damaging the surrounding area if possible.

I'd apperciate advise on cutting the hole to mount the light and recommendations on what brand of light to go with.

Thanks

[tobyw]

I've done this sort of thing a few ways...

1.) 1/2" drill motor and a hole saw. This works, but it is extremely important to keep the drill level and the speed under control so you don't ruin the hole saw, and more importantly so you don't rip your arm off

2.) Magnetic drill. For a clean hole in a vertical surface like a bumper face, this is the best plan of attack IMO.

3.) Plasma cutter. Since you are using a grommet, you have some wiggle room and 100% accuracy in your hole isn't necessary. It's fast and easy, but if you're not skilled in using it or your consumables aren't in good shape, it can leave you with some cleanup on the inside of the hole that is a PITA to access.

[White trash]

Toby is right on all counts for the hole. But I'd rethink the light, leds are great in most applications but reverse lights aren't one of them. Use the same 4" grommet but slide a 4" tractor utility sealed beam in there if you really want to see.

[SquirrelCrusher]

I don't have access anything but maybe a drill. Plasma would be nice, but wouldn't it mess up the paint around the hole past where the grommet would cover?

Thanks for the advise on the light. I thought LED would be good for reverse lights. I'll look at regular lights

[SPR]

I have a magentic drill and cutting oil. Bring you rig, a new 4-hole saw and pint a of R&R, to my place and I will set you up.

[SquirrelCrusher]

Might have to take you up on that SPR, but the bumper face isn't straight up and down. It is at a slight angle. Will that matter?

[White trash]

Mag drills don't care what the angle is...

[colemancooler]

use masking tape to cover the cutting area, if you care about the paint

[SquirrelCrusher]

4" is going to be to big. The bumper is only about 4.5" wide so i think something a little smaller would work better. Or maybe an oval shaped light? I can't seem to find round lights in 3" or 2". Do they make grommet mount lights in 3"?

[SPR]

Did you look for lights at Ranch and Home in Kennewick? They have a hugh selection.

[SquirrelCrusher]

No I just got into town yesterday. If I have time today I'm going to go check out there.