Yzer’s Grillcraft Fog Light Grill installation mod

Owners of the 2002-2003 WRX are lucky to have some very nice stock fog lights mounted in their stock front bumpers. The lights are adjustable, and once they have been properly and legally aimed from Subaru’s useless low-angle factory setting they make excellent fog and driving combination lights. Unfortunately, these lights are subject to breakage from road debris. Repair or replacement of a lamp is expensive. To prevent this damage (and to improve appearance) fog light grills may be mounted in front of the WRX fog lights.

For my taste, the Grillcraft mesh fog light grills are the best-looking. They are nicely made and do a fine job of protecting the lamp lens, too. I was able to buy them for $99 and no shipping charges from www.eautoworks.com during the first week of December.

I held back from buying the Grillcraft grills for nearly a year because they have two major drawbacks:

1. They are mounted permanently. What good is a grill if you can’t easily remove it to clean the light?
2. Grillcraft recommends that the stock upper grill, the headlights and the front bumper be removed to install their grill. OK. I can do that, but I’d rather not if I don’t have to.

Here are the Grillcraft factory instructions: http://www.grillcraft.com/installs/i...ew&install=114

I modified installation of the Grillcraft grills with the following improvements:

1. They are now easily removed and replaced. The fog lights may be cleaned whenever necessary.

2. No disassembly is required for installation.

3. The fasteners used in this installation will not rust or corrode.

The Grillcraft Fog Light Grill, installed as described below.

 

Looks like broken sunglasses. There is a mounting pin on the outside of each grill. A mounting tab with a factory-drilled hole is found on the inside of each grill. Middle, top: Grillcraft kit fasteners are the two U-clamps and two cadmium-plated screws. Middle, bottom: this mod requires use of the screwdriver and screws described below. They may be purchased at the hardware store for less than $3.00.

Three additional items required for this mod:
A. One small Philips head screwdriver. The shaft of this screwdriver must be at least 2½ inches long (mine was 2 and 5/8-inches) and the shaft must not be more than 1/8-inch in diameter. Find it at Ace Hardware. Don’t use a slotted screw and screwdriver, they will be difficult to use with this application.

B. Two screws. I did not use the supplied cadmium-plated screws because they are subject to corrosion and a smaller length is required for easy removal and re-installation of the grills. Required screws: Two (2) No. 8 Philips pan-head stainless steel 3/8-inch sheet metal screws. Go to the fastener bins at Ace Hardware.

 

After marking, use a 3/16-inch drill bit to the hole for the mounting pin as shown in the Grillcraft instructions packed with the kit.

The mounting pin hole goes into the single thickness of painted bumper material just in front of the black plastic surrounding the lamp. Take it easy, the plastic is not very thick.

 

The fun starts after putting the Grillcraft instructions away and tossing out the Grillcraft fasteners.

Insert the grill mounting pin into the hole you just drilled (snug fitting, to prevent rattling) and carefully place the grill into its mounting position. You can hold the grill in place with one hand if you like, and the screwdriver with the other. Carefully insert the screwdriver through the mesh as shown. The small driver will not contact the mesh material if you do this carefully, and will not enlarge mesh holes or mar the powdercoat finish. Looking through the grill, place the tip of the screwdriver in the middle of the mounting tab hole and on the black plastic surround. Using a light source like the shop light in the picture will make it much easier to check that you have your mark centered. Mark the center on the plastic with gentle pressure and rotation. After marking, remove the grill and set it aside. TIP: When removing the grill, keep a finger between the mounting tab and the bumper to prevent scratching when the grill pops loose.

 

OK. Sorry, this picture looks weird, like I’m trying to drive a screw with a drill bit… I’m not. I just want to show you the drill with a smaller bit and the mounting tab screw in its place. My apologies for the particulate insect matter on the bumper (the little buggers never knew what hit them): it has been raining and the WRX hasn’t been washed in two weeks.

Mount a 3/32-inch bit onto the drill. Holding the drill steady with both hands, place the tip of the bit onto the mark and drill the pilot hole into the single thin piece of black plastic surround. Don’t forget the next step: Carefully drive your stainless steel screw straight into the pilot hole about ¾ of the way. Do not tighten the screw! Drive the screw back and forth a few turns to size the hole and cut a thread. Remove the screw.

 

The easy way to fasten the mounting tab.

It’s time to finish mounting the Grillcraft grill and it’s easier than it looks. Place the mounting pin into its hole and leave the inside edge of the grill hanging out. Place the stainless screw into the mounting tab from the inside of the tab.

Carefully insert the small screwdriver through the mesh and into the screw head. Don’t worry if the screwdriver does not line up straight with the screw head: only very light torque will be needed to tighten the screw and the Philips head will allow for this kind of misalignment. The screw head will not be stripped. The two will stay connected just as they are or you can hold the screwdriver with one hand and reach around with the other to hold the screw in place.

Keeping the driver and the screw together, gently push the grill into place. Let the screw and the screwdriver slide lightly along the black plastic surround until the screw drops into the sized and threaded hole. This gets very easy after doing it the first time. Use light force to screw the mounting tab and plastic surround together. DO NOT OVERTIGHTEN! Turn the screw only until you feel the resistance increase as the screw, mounting tab and black plastic surround come together, and then stop tightening. Look through the grill with a light to check this the first time. Just a barely snug fit will hold the grill in place securely and will hold up to being mounted and re-mounted an indefinite number of times. It takes me less than a minute to re-install the grill after cleaning the fog light.

If the screw is over-tightened, the hole in the plastic surround may be deformed or enlarged and may not hold the grill securely. If that happens, you may be able to get around the problem by using another screw that is one size larger (No. 10).

 

Here is the screwdriver in position for easy attachment or removal of the Grillcraft Fog light Grill.

 

The grill fits perfectly and the stainless mounting screw does not look obtrusive through the mesh. Keep the screwdriver in your WRX so you will always have it when you need to clean the fog lights.

You may have noticed, but I really like these Grillcraft grills.

 

Very cool, and great instructions. But I like my mesh replica covers I got for about $50 on ebay. Took me about 10 min to install (plus time replacing the mounting screws that snapped off, oops). I think they look sweet and would be perfect if you have a FMIC and had to remove the stock lights. Both are nice options, but I like mine best, especailly unpainted for a nice contrast to the silver.

 

Those are nice covers. Fog lamp grills really change the look of the bugeye WRX's. I noticed when coming out of the grocery store today and making the long walk to the far side of the parking lot (where I am less likely to get door dings) that my car looked different. It always used to look like it had four headlights, which is kind of cool. Overall though, the mesh screens look great, especially when the lights are on. You got a great deal on the covers, too.