Demello front bumper install troubles

[Panzerpatty]

Installing a 3 hoop Demello front and the mounting holes don't line up, off by maybe a 1/8 inch. The tolerances are tight. I've tried as many up/down/left/right orientations I can. Demello himself said there would be troubles getting it to fit at first. Although at this point, after 3 hours of fiddling, I think it's a manufacturing error.

Does anyone have any tips on a job like this? I'm hoping there is a magic bullet to get the fit right.

 

[wfo9]

couple of things... you will need something to keep the bumper up in the air.... Jacks (people....). Leave an air gap while getting all the bolts on initially.

Worse case. Some of the holes may need to be widened a bit with a step bit...

I know it sucks, but not that uncommon with large spans like that.

It could be a flaw in the JIG... but usually resolvable with a little work and a few choice words....

 

[Panzerpatty]

Thanks,

I was using people but they were only here yesterday. What kind of jacks do you recommend for this kind of job? I only have a Hi Lift and bottle jack.

couple of things... you will need something to keep the bumper up in the air.... Jacks (people....). Leave an air gap while getting all the bolts on initially.

Worse case. Some of the holes may need to be widened a bit with a step bit...

I know it sucks, but not that uncommon with large spans like that.

It could be a flaw in the JIG... but usually resolvable with a little work and a few choice words....

 

[Engineer]

I think both those jacks would be hard to use due to stability issues. A standard floor jack with a rubber pad to "balance" the bumper on would likely be the best.

Another thought, if you have access to threaded rod (this way you can make some long bolts....) and some nuts you could make a set of guides, temporarily install using those instead of the standard bolts to hopefully get a better feel for how tight things are and if enlarging the hole will be enough.

Good luck

 

[wfo9]

Thanks,

I was using people but they were only here yesterday. What kind of jacks do you recommend for this kind of job? I only have a Hi Lift and bottle jack.

For stuff like this... I have two floor jacks. I also have old rotors that I use on them to balance odd stuff. Plus 4x4 wood blocks...+ straps. It takes some creative solutions....

Another thing I have used is an engine hoist.

 

[Panzerpatty]

Just tried again and confirmed it is a manufacturing issue. I'm not really sure how to proceed. I've never drilled into something like this before and I'd rather not have my training be on a $1500 bumper lol. Thanks for the help!

 

[1engineer]

Just tried again and confirmed it is a manufacturing issue. I'm not really sure how to proceed. I've never drilled into something like this before and I'd rather not have my training be on a $1500 bumper lol. Thanks for the help!

If it's only off 1/8" simply slot the holes a 1/16" on either side. If you are not comfortable with this then pay someone to install it for you. They'll slot the holes and not bat an eye. Go to a local body shop, tell them you can't do it and you'll pay to have it done.

 

[Watchdogg]

I had to use a round file on my Shrockworks bumper to fit also. Same thing, about 1/8 inch. Powder coat and a little metal.

 

[SSDuck8]

I have known some other with the same issue but getting the jack stands may help you out tremendously