Demello LB (LightBar) Baja Bumper Install / Review

Hi, while this is fresh in my mind, I thought I would wrap up my install notes. I did the install this week by myself over 2 days in the driveway. Day 1 was cutting and cleaning up the stock plastic bumper (2-3 hours) and Day 2 was the wiring and install (6 hours). I'm an experienced mechanic and I've cut into vehicles before. If you aren't comfortable ruining a perfectly good stock bumper, find someone who is. Once you do that first cut, there's nowhere else to go. I was able to position and mount the bumper myself, but I can also deadlift >500lbs. So, if you can't do that, probably get a friend or two. This thing is super heavy.

After I settled on the Demello bumper because it ended up being my favorite, I had it quoted. Right before I ordered it, this new bumper popped and and I bought it locally. FYI, for the folks that don't care for the DO laser cut logo in the front of the non-LightBar bumpers, you can order it without the DO logo which is what I was going to do.



For outfitting this thing with lighting, I opted for the $265 Baja Squadron SAE driving lights (Street legal) and the $179 Rough Country 30" Black Edition Light Bar. Not a bad score. I did order a light bar switch for the dash, but the Rough Country has a 3-position switch for marker LEDs/OFF/ON. Both kits come with tons of wiring to install. The Rough Country kit had relays, fuses and nylon wrapped cable and waterproof connectors.



Ok, first step and the most unnerving, cutting the stock bumper. No going back. I went to harbor freight and picked up the small angle grinder that can take the thin 3" discs. I felt the 4" was too big and a dremel too small. I did use Demello's measurements and they turned out very well.

 

Stock bumper is off and all of the edges cleaned up. Stock crash bar off. Take your time on the edges. No reason to rush here.




You can leave the center section of the bumper cover intact, BUT you do need to pull the 4 stock plastic rivets so the center can push back. to make room for the grille. That's how close the bumper is to the grille and surround. When you go to remount the grille, it will NOT go in unless there is give in the center section. It took me a while to figure this out.



Mount all of the lights, winch and license plate to the bumper first. You won't have good access when the bumper is mounted.

 

The FITMENT on this bumper is just incredible. After mounted and massaged, the difference in the sides that sit against the fender flare is flush on one side and maybe +3mm on the other side. If you think about the variability in manufacturing of our trucks and the bumpers, my mind was pretty blown.

 

Final result.





Now I'm not a big flashy off-road light guy. I like good headlights and good driving lights. However, I gotta admit, the light bar is actually pretty cool. I love how the lightbar has a low output driver light setting. It kind of brought out the 16 year old kid in me with my first F150 that I probably put like 10 KC lights on haha.

 

Looks good! Bold move with the HC steel bumper and stock splash shield!

 

I'm not sure I understand this. Can you explain?

 

Just giving you a hard time. Most people go with some real skid plates, sliders, etc. before going in deep with a full plate bumper since there aren’t many situations where you will need a bumper like that that won’t tear up your rockers or the thin stock skid.

Bumper looks great! Wish my cuts were that clean!

 

He is poking fun at the fact that you have a badass rugged bumper with that flimsy “skid plate” Shield.

 

let’s see your bumper / cuts

 

I don't know, I see a lot of people here spend over $1k for headlights that have LEDs in them. Bumper doesn't seem that extravagant.

 

Bumper looks great. Your cuts look fantastic

 

Looks good man, you've been busy!

 

Nothing wrong with enjoying your truck the way you want to enjoy your truck!

 

Nice. OP has you beat on them cuts. It’s like he laser beamed those suckers. Lol

 

For sure, although with the way I beat on this truck you need a little more space than he has between the steel and factory bumper. Unfortunately the way the body mounts are there is still a ton of flex.

 

I figured the bumper has flex paint on it so it shouldn't crack right?

 

Nice write up and good lookin truck!

 

Looking good! Thanks for the write up.

 

Quick other note. I put the Baja Design Squadron SAEs in the driving light spots. I initially just bolted them directly to the bumper like this. They weren't centered vertically which was fine initially, until I realized when I was trying to aim the lights that the lights' bodies hit the bumper before they were aimed properly down.



So, I removed them and added an aluminum spacer under the light that I had hanging around, maybe .25". Now they are more centered in the bumper and I can aim them properly.