To read the original full thread and post questions/comments on this topic, please go to https://www.fjcruiserforums.com/forum...-brackets.html
Tin Can’s Do It Your Self: OEM Air Dam light Brackets
Hello and welcome to yet another do it yourself installment for the FJ Cruiser. Today we will be making OEM air dam light brackets/mounts.
List of tools/miscellaneous items:
• Drill Bits and Drill
• 1/8 Aluminum Flat Bar
• Stainless Steel Hardware (Optional)
• Double Sided File
This DIY is very wordy on purpose, so that there is no question of what to do. I’m going to make the basic assumption that one knows how to use power tools. This DIY is written making only one side, the sides are the same just repeat the steps to make another. Note: These tools can also be used to do a jail break…lol!
Step 1: Cutting the Aluminum Flat Bar (Top)
Locate the 1/8 thick flat bar (Picture 1) measure out a 2” line, using the hacksaw cut along the line. Now, take that 2” top plate and file off the rough edges (Picture 2). Then, test fit the top plate on the air dam (Pictures 3a, 3b, 3c & 3d). There should be very minimal movement, move to step 2.
Step 2: Cutting the Aluminum Flat Bar (Bottom)
Locate the 1/8 thick flat bar, measure out 2.5”- 2.75” (I used 3” it was a little too long) using the hacksaw cut along the line. Now, take that 2.5”- 2.75” bottom plate and file off the rough edges. Then, test fit the bottom plate on the air dam (Pictures 4a & 4b). Move to step 3.
Step 3: Marking the Bottom Plate
Locate the bottom plate; test fit the bottom plate to the air dam. Next, using the marker, trace the ring of the air dam from the top, on to the bottom plate (Picture 5a & 5b). Move to step 4.
Step 4: Marking/Drilling the Top Plate
Locate the top plate; using the ruler measure out the center point of the top plate mark with marker. Now, use the punch on that center mark. Then, drill a pilot hole on the center mark; continue to step up to the desired diameter (Picture 6). Move to step 5.
Step 5: Marking/Drilling the Bottom Plate
Locate the bottom plate; using the top plate as a template trace the center hole on to the bottom plate with a marker (Picture 7). Now, use the punch on that “center” mark of the bottom plate. Then, drill a pilot hole on the “center” mark of the bottom plate; continue to step up to the desired diameter (Picture 8). Using both the top plate and the bottom plate, test fit the two (2) plates on the air dam (Picture 9). Move to step 5.
Step 5: Mounting Hardware
Locate the hardware you are planning on using, I used stainless (Picture 10), I don’t like rust. Test fit all the bolts and nuts, they should fit perfectly straight down, if they do not you may have drilled a little off center (Pictures 11a, 11b). Finish, mounting lights and hardware (Pictures 12a & 12b). To do the other side, repeat the steps. Thanks and enjoy, PM me if you get stuck!