Help with custom install
 

So here's what I'm doing to the lower bumper area:

http://i269.photobucket.com/albums/j...pscae97258.jpg

Here's the progress I've made so far:

Lower bumper opening without insert:
http://i269.photobucket.com/albums/j...ps9ee48a87.jpg

Cut out the vertical supports:
http://i269.photobucket.com/albums/j...ps03c8085e.jpg

This is just to show how much of the space the bar will fill. The bar is just sitting on the lower bumper:
http://i269.photobucket.com/albums/j...psb26cb448.jpg
http://i269.photobucket.com/albums/j...psf769f67b.jpg

As you can kind of see here, the lower insert not only curves up but curves in as well:
http://i269.photobucket.com/albums/j...ps2ae109b8.jpg
http://i269.photobucket.com/albums/j...ps62b24988.jpg

My issue here is that, obviously, the bar does not curve in any way. So here is the only option I can come up with. I would cut along the red line you see here:
http://i269.photobucket.com/albums/j...ps9ff56b90.jpg

Now, I could either leave it wide open and the bar would just sit back a bit in the center OR I could fill this area with some sort of black mesh. I like the mesh idea, but then again I don't because the upper grill is not a mesh.

Thoughts?

I have metal billet inserts that you could just have and see if you could install them somehow. They would need to be painted to match, but I think they'd go good with the rest.

The billet would look better, then I'd make the cut before going with the mesh.

I think I would just cut out the red portion and leave it at that. With a little tint on light bar, I think it will all blend it great.

If you do the mesh or billet options, you'll have to make sure it's curved right or it might look off...

That's my concern as well. I don't know anybody who is good enough with metal to make it bend that way. I would also have to fab up a way to mount the billet insert.

I'm thinking of going to my tint guy and seeing if he can just lay a light layer of tint on the lense. The cheapest option with Lamin-x will leave me with over 50' of tint left but with a max width of 5", it wouldn't have much use.

how deep is the led bar?

can you just cut a part out of the insert and the bar fills it? And yeah, you'll have 1" at the bottom and its flush at the top? that kind of deal?

Didn't think about window tint. Would that hold up to the heat?

side note...........kinda surprised with this mod. Interesting addition to the truck David!

tinting plastic is tricky bc if you decide you don't like it or it fades real easy or anything makes getting the adhesive off that plastic extremely difficult i would cut the red line and then go from there .. if you don't like it you could always add mesh to it later ...

I'm not big on the mesh idea just because it wouldn't match. BUT.... Do the mesh and get a nice looking black mesh grille? Otherwise I would just make the cut and leave it be