So it begins...
Step 1 - Remove fog lights. No pics of this, just push the tabs in on either side of the adjuster screw and pull the light straight out.
Step 2 - Cut the lens off the fog light housing. I used a dremel tool for this with a cutting wheel. Wear safety glasses for this, the lens material is a hard plastic and it does make a mess. Don't cut in too far or you'll go into the chrome plastic on the inside (I did this in a couple places by accident). See lessons learned, I found a hack saw is a better way to remove the lens vs. the dremel.
Step 3 - I cut off the fog light housing back where the light bulb goes in. This made it easier to use the hole saw in the next step. See lessons learned, leave this piece in place and it acts like a guide for the hole saw making sure you stay centered on the housing.
Step 4 - I used a 2" hole saw to cut a hole in the fog light housing. You'll notice the Blazers aren't round at the back though, they're more of an oval. To make the hole more oval, I used the Dremel tool attachment that looks like a weird drill bit but cuts sideways (not sure what it's called).
Mock-up of what the final product will be (minus the shrouds, I needed another set of hands to hold the shroud in place). Make sure the lens will clear the projector when put back on. This looks like it sticks out quite a ways but the lens will still clear by 1/4 - 1/2".
Step 5 - Off to the paint shop (AKA my basement). I decided to black out the shroud and the housing so the fogs will have a blacked out look until flicked on.
Step 6 - Do plenty of mock-ups and when you're satisfied with the fit, JB Weld the projectors in place, again make sure the lens will clear the projector. I used alligator clips to hold the projector where I wanted and hung it from the ceiling then applied the JB weld. I think I'm going to apply silicone over the JB Weld also to make sure it's water tight. Hanging by the projector seemed to be the easiest way to make sure everything stayed put.
Step 7 - Trim shroud and epoxy in place (JB Weld). When you trim the shroud, remember that if you just trim it square, it will only contact the reflector bowl on the edges. You need to make arched cuts to make sure everything stays tight so you can epoxy the whole shroud base. Again, I made the mistake of just trimming the shroud square.
Step 8 - Reseal the lights! Make sure the inside of the light is nice and clean, use a lint-free cloth to wipe everything down, wipe off the projector lens and thoroughly clean the inside of the fig light lens. Test fit the lens, make a mark so you know the orientation. There is an SAE stamp on the front, I make a mark over the A so I knew which way it fit best. Run a thick bead of silicone around the fog light base and put the lens on. I used my finger around the edge to smear the silicone around the edge for a good seal. Remember, you only have one shot at sealing these things up. It's not like your headlights where you can just throw them back in the oven to open them up again.
Step 9 - Remove Tape
Step 10 - Drink Captain
First light done! I only did one at a time because my passenger fog light was already leaking so it was a good one to experiment with.
Second light underway...