How to install brush guard/grill guard

my article will tell you the steps to reducing your chances of having damage to the front of your vehicle when off-road or in a minor wreck.

Instructions

Difficulty: Moderately Challenging

Things You’ll Need:

• Grill-guard and brush-guard kit including installation hardware Socket-wrench set Electric drill Electric cutting tool or small saw Silicone sealer

1. Since this project will involve some work with electrical wiring (disconnecting the bumper lights), disconnect the negative battery cable before you begin work.
2. figure c The grill guard is attached to the vehicle by means of frame-extenders that bolt on to the frame. Installation will require first removing the bumper, which in this case is held on by two bolts. Disconnect the bumper lights before you lower the bumper. You'll also need to temporarily remove the tow-hooks, also held in place by bolts.
   
   (Important: Take note of the factory alignment of the bumper before you remove it. You'll be duplicating the original alignment when you reinstall. Take special note of the spacing between the top of the bumper and the bottom of the grill and headlight-mounts.)
3. figure d With the bumper removed, the extenders insert into the openings in the end of the frame and are bolted in. Loosely install the rear bolt that holds the extender in place. Before you tighten it all the way, however, slide the tow hook in place (figure C). You can then loosely install the bolts to hold both the tow hook and the extender in place (figure D).
   
   Before tightening down the bolts completely, make certain that the frame extensions are centered. According to the manufacturer of these guards, a distance of 31-1/2" from one extension to the other will ensure proper centering. Once you've checked the centering, tighten down the bolts securely.
4. figure e Once the extenders are attached to the frame and properly spaced, you'll need to cut openings in the bumper. Two openings are cut in the lower plastic portion of the bumper for the insertion of the extenders. Two others will be cut in the upper portion of the bumper for securing upper mounting brackets that come with the kit. (These replace the existing factory mounting brackets that hold the bumper secure.) The manufacturer supplies diagrams showing the locations where you'll cut the openings, but it's still advisable to hold the bumper up to the extenders to double-check the locations. Mark the locations, then cut the openings (figure E) with an electric cutting tool (e.g., a Dremel tool) or small saw blade. Once the holes have been cut, install the new upper mounting brackets according to the manufacturer's instructions.
5. figure f With the frame extenders and new upper mounting brackets installed, reinstall the bumper. Take care to line the bumper up precisely since the alignment of the grill guard will be based on the bumper's alignment. The extenders should fit properly through the holes you cut in the bumper (figure F) Once the bumper has been attached, plug the bumper lights in.
6. figure g With the bumper reinstalled, and the frame extenders and the upper mounting-brackets all installed, you can begin a rough assembly of the grill guard (figure G). Follow the kit instructions to install the side members to the upper brackets, and then install the cross members (the upper tube and the lower winch-mounting plate) between the side members. Put all the parts in place, but assemble them loosely. You'll need some maneuverability to make final adjustments before tightening everything down.
7. figure h The next step involves some drilling through metal. The bottom of the side mounts do not have predrilled holes (for attaching to the frame extenders) like the rest of the assembly since exact placement for these may vary slightly between vehicles. You'll need to adjust the fit of the side members and check the alignment and clearance of the components in relation to the bumper. (This kit includes shim plates that, if needed, will help the side members and frame extenders fit exactly.) Once you have the proper alignment and clearance, clamp the side member to the frame extender and, using the frame extender as a template, drill holes in the side member to match the ones in the extender (figure H). Do this step on both sides.
8. figure i Insert the bolts to attach the lower portion of the side member to the frame extender, then install the lock-washers and nuts (figure I) and tighten securely.
   
   Tip: Use silicone to coat and seal the newly drilled holes and the base of the bolts in order to prevent rust.
   
   Tighten up the entire assembly securely.
   
   Follow the manufacturer's instructions to attach diagonal braces that support the lower cross member (the winch-mounting plate) by attaching it to the frame.
   
   With the grill guard installed, mounting the brush guards is fairly simple. These require no drilling and simply bolt on to the side members. Nylon washers serve as spacers between the side member and the base end of the brush guard. Adjust the outer ends of the guards for best alignment with the lights, and so they don't scratch the painted surface, then tighten the bolts securely.

Tips & Warnings

• always wear safety glasses when doing this to avoid injury to eyes from flying parts.