Journal of Automobile Projects: I Was Uncertain About How to Attach My Elegant New Bumper so I Opted to Begin Turning the Wrench

Automotive bolts are typically located in inconvenient positions. Being able to maneuver a shape-retaining squirt tube into tight spaces and around obstacles is a definite advantage. Even when dealing with rusty bolts that are accessible, I appreciate the precision achieved with this applicator. These advantages were heavily utilized as I removed the bumper from my truck. I absolutely do not miss the era of those annoying little red plastic squirt tubes that would frequently go missing or fly off during a project.

Prior to even beginning work on the Montero, I treated every accessible bolt with a few sprays of penetrant. I understand, it might sound like a line from a penetrant salesperson, but trust me—the longer the substance has to act, the more effective it becomes. An effective penetrant can be the difference between effortlessly removing a bolt and it snapping off, resulting in a painstaking rethreading task. When it comes to penetrating fluid: Start early, apply frequently.

Thankfully, removing the front bumper of a ’98 Montero is relatively straightforward compared to newer vehicles. I simply had to disconnect the headlight washers (loosening hose clamps and gently pulling rubber tubing), disconnect the factory fog lights (unscrewing the bezel and unclipping), and then detach the skid plate. The bolts on the skid plate were easily accessible but quite corroded. I gave them an additional spray of penetrant. From there, the bumper was resting on the frame and secured by four unusually long horizontal bolts.

The bumper came off within minutes. It took longer for me to relocate the bumper from the truck to my workbench in the cramped garage than it did to actually unbolt it. Even when compared to other vehicles from that time period, removing the front end of this vehicle was surprisingly effortless.

Upon obtaining this protective grille, I initially presumed I could attach it while leaving the bumper intact on the vehicle. That is the typical method for installing such grilles. However, I soon realized that two of the attachment points were concealed beneath a chrome piece that could only be accessed from the rear.

Having the factory bumper on my worktable, I soaked a few more bolts with a penetrating solution and commenced disassembly. The bolts were easy to spot again. However, it was apparent that these bolts were secure in their positions—thus, each received a penetrating oil treatment before attempting to use a socket. Only then did I encounter complications.

In every available picture of a Japanese Montero (known as Pajero overseas) featuring this grille, it appeared to be attached to the same chrome main bumper I possess. However, it became clear that the resemblance was only superficial. The attachment points of the grille did not align precisely with the bolts I presumed they should.

Two small plastic protrusions seemed to be obstructing the progress of the grille from fitting snugly; these were easily removed as well… but creating insufficient space for the grille. Darn!

At that moment, I understood that I had to either modify my bumper or devise an adapter for the grille. Alternatively, I could revert to the original configuration and use the JDM grille and lights as decorative pieces, which would be equally appealing.

Setting that consideration aside, I directed my focus to the smaller set of lights that fit into the corners of the factory bumper. It is no surprise that the mounting bolt of the KC light does not align perfectly with the Montero’s existing light bracket. However, it appears feasible to drill a small hole and craft my own adapter without much difficulty. I am experienced in this area and have full confidence in overcoming this challenge.

The original fog lights on this vehicle have never functioned for me due to the prior owner’s unconventional wire tampering for a now-removed aftermarket light setup. Typically, I’m dedicated to maintaining the vintage appearance of this vehicle and hesitant to swap factory fogs for modern LED ones. However, in this instance, the KCs will be predominantly hidden by the bumper and won’t disrupt the ’90s style of the truck.

I initiate the removal of the stock fog lights, which entails, you guessed it, the reapplication of penetrating fluid. I specifically chose to highlight WD-40 Specialist Penetrant with EZ-REACH for this task as it plays a critical role here!

Eliminating old fog lights proves to be a surprisingly challenging endeavor as they are typically secured with small rusty screws. This scenario is ripe for stripping screw heads, and employing a torch is infeasible due to proximity to plastic components. Penetrating fluid comes to the rescue—I soaked the retaining screws in penetrant and allowed them to marinate while devising my next steps.

Even if you have no plans to uninstall your fog lights, applying penetrating fluid to any exposed light adjustment screws is highly recommended. This will prevent the spring from seizing up if and when adjustments are needed.

Trying out the brush guard on the bumper, even off the vehicle, proved a bit tiresome. Handling two large chunks of steel is quite unwieldy. Understanding that this isn’t a simple plug-and-play situation, I need to strategize my next move. Should I reinstall the original bumper and search for a complete JDM bumper to match the JDM brush guard? It might be costly. Alternatively, should I fabricate an adapter to mount the JDM brush guard onto the USDM bumper? This will require precision as the brush guard is heavy, making the mounting solution crucial. Improper fitting could result in increased damage in case of a front-end collision. Or perhaps I should abandon the idea, hang the Japanese piece on my wall (I already have a spot in mind), and stick with the stock setup along with the KC lights.

If I do opt for the Japanese bumper setup eventually, I’ll also need to figure out how to mount the lights on it. Initially, I assumed they would align perfectly since their mounting holes seemed to match those on the brush guard. However, upon closer examination, I noticed slight differences in the angles.

The lights I acquired are Mitsubishi factory-made from a similar era as my Montero. They feature a curved mounting base, probably designed for attachment to a cylindrical bar. To use them with my bumper, I could either create an adapter or adjust the mount’s shape. While not overly complex, this is a challenge that must be addressed. When it comes to mounting such large lights, ensuring a sturdy attachment is crucial. These lights will face significant wind resistance and might sway if not properly secured. Driving with loosely mounted lights is unpleasant for both yourself and other road users.

At this juncture, I’ve spent considerable time contemplating and rearranging parts in close proximity, pondering without making much tangible progress. Indecision has been my primary obstacle—deciding whether these accessories should adorn my truck or serve as ornamental wall decorations.

I wouldn’t necessarily suggest engaging in improvised mechanical work like this for every project; however, sometimes merely reviewing diagrams, videos, and online discussions is insufficient. In the end, one may have to conduct some investigative disassembly—stripping away certain car components to discern precisely what’s necessary for a successful project.

Although I may still be somewhat undecided on the next steps, I did manage to disassemble the front portion of my truck easily with the appropriate tools!