2005+ V6 Mustang... Cutting a hole for dual exhausts?
Has anyone ever cut a hole for their bumper? I don't know if I want to do that...if I screw up, that would be baddd. What kind of materials would u need to complete this task?
Has anyone ever cut a hole for their bumper? I don't know if I want to do that...if I screw up, that would be baddd. What kind of materials would u need to complete this task?
The bumpers are polyurethane and very hard to cut cleanly (the plastic molds beautifully, but it crumbles and rides up in ridges under the assault of saws and such).
Don't do it.
Save your pennies and buy a GT rear bumper. Sell your bumper (its worth almost as much - especially if you buy used).
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tripleblack
"You can never be free until you let yourself go."
Go to the Pypes website and download the free template.
Dremel is the tool of choice. Fine sanpaper an touch up paint for the edge.
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Xcharger with water injection, JBA headers
JBA duals with an H pipe, Roush rear springs, Che K member brace with torque limiters, Cervini's quarter window deletes, Canton polished expansion tank, Roush scoop, Street Scene Elenor grille, custom GT500 chin spoiler, PJ rear louvers, Black rear spoiler, BSM custom stripes, Hurst shifter, Billet interior trim, custom door welts, Autometer dash pod, AEM wideband, Autometer boost & Fuel pressure gauges
Now that template is cool.
The bumper is urethane and is easy to cut but is also easy to mess up. The Dremel with a drill bit can actually be used to scroll around the line you want. Don't do it right on the line, do it slightly inside it so you can smooth out the edge. I've done this on mine, I know it's an 88 but the theory and process is the same.
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MOOG Certified Tech. For mods and sound clips, see profile and gallery.
Ask me why I ran "only" a 13.54.
Member: NMRA Member: White Mustang Registry #362 Member: Fuzzy Dicer
Just use a dremel...as previously stated just stay inside a little bit in case you need to sand it down. Also keep in mind that it wont look prefect because the original side bumper curls in whereas your cut will look like a sharp edge. It may look a little bit off but it really isnt.
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2005 Screaming Yellow V6 Mustang - 5 Speed Manual, In Dash DVD/Navigation, Eibach Pro Kit, 10" Black Stripes with 1/2" Pinstripes, 10" Sub Woofer with Sony Amplifier, 20" Foose DF-5 Rims with paint matched center pieces.
2009 Shelby GT500 - White w/ Red Stripes - Stock (For Now)
I carried mine to the local community college body shop they cut it for $10 and it looks great, plus if they had screwed it up thier insurance would have paid for it. I'd reccomend taking it to a reputable body shop or your local community college, but don't pay very much.
I carried mine to the local community college body shop they cut it for $10 and it looks great, plus if they had screwed it up thier insurance would have paid for it. I'd reccomend taking it to a reputable body shop or your local community college, but don't pay very much.
problem is, I couldn't find a body shop that would touch it. They didn't like cutting a brand new car's bumper... you'll probably find others like that. they would try to say that it would mess up the "support" it needed... it's a bumper COVER!
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*1998 Ford Contour SVT* EH 2.5L Duratec v6
Stock as can be, just trying to reverse the damage the previous owner caused.
I did the cut out myself a while back. It is not that bad if you just take the entire bumper cover off and work on it in your garage. Just make sure you measure twice. I made a cardboard template by tracing the hole on the other side. If you do this, make sure you flip the template over so it's a mirror image (the hole is not a perfect circle so I would recommend against using a CD as a template). Then I used a mini, hacksaw to cut the hole. Then I went back with a dremmel tool with a sandpaper attachment to shape the hole and smooth it out. Just take your time with it. Don't get impatient. It doesn't have to be perfect, because of the way the bottom part of the bumper cover slopes inward, you really won't even see the shape of the hole especially when it is filled up by another exhaust tip. Do it yourself and save some money. I personally like the look of the V6 mumper cover better than the GT. I don't like that lip at the bottom of the GT one. Just set aside about 3 total hours and you can knock it out no problem. I did a write up on this a while back. Do a search on V6 bumper cutout and you should find it. The dremmel is your friend. Just take a little bit out at a time with the dremmel and the sandpaper attachment until you get it just right. I had numerous compliments on the job I did, including from my mechanic, that it looked OEM.
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"Their are two types of pedestrians: The quick and the dead"
-unknown
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05 Satin Silver V6/Automatic/NO Traction Control NO anti-lock brakes (can't stand either one)/TI CAI w/ SCT Xcal2 93 Octane Bamachips Torque Tune/Pypes true dual w/x-pipe and Violator mufflers/Alpine Head Unit w/ iPod jack/XM Delphi SKYFi2/Alpine rear deck speakers/Molded splash guards/Steeda Dead Pedal/GT takeoff front and rear sway bars.
Here's what I found, the opening is not true round so a cd is close but not right. The pypes template is also a little off. I took a sheet of paper and taped it to the bumper over the passenger side opening, use the body lines and the plastic tab under the bumper towards the license plate as reference points. Mark these with a penceil then trace the outline of the opening. Cut out the opening and flip over, now line up on other side using your reference marks and tape securely. I used a coping saw and slowly started cutting staying off the template a little. The plastic cuts easily. Then go back with a dremel type tool and barrel sander and clean it up, them some sandpaper. It really is not that hard, and you can't really see the opening unless you get on your hands and knees. Use some touch up paint on the cut as the bumper is black under your paint. good luck. Had a local muffler shop make drivers side pipe and cut into Y, looks good but alittle unbalanced and I get a vibration at idle. In the spring I think I will buy the Pypes true dual setup for $300.00, the duals due look good.
2005+ V6 Mustang... Cutting a hole for dual exhausts? 
