To view more pics of the finished mod, here is my original post:
*** DISCLAIMER ***
I used Phillips Daylight-8 DRLs for this mod. You can also use Phillips Daylight-4 DRLs for this mod, the difference being that the Daylight-4 model will not be as long as the Daylight-8 and therefore will not fill the entire lower section of the grille insert. If you are using any other brand (and, really, why not use the best?) ... you may not get the same results. Also ... My M is a non-sport model so my bumper is a slightly different design than the M35-S. However, if the grille insert area is the same size, then Daylight-8's should fit nicely. If the grille insert area is smaller, try the Daylight-4 kit.
Please don't try this at home unless you ask your parents first - batteries not included.
When I went to the driveway to take some pics today, Fetucini told me she already took pics at various points of the mod with my GoPro. I looked through them and used a few to make this DIY.
You will see little black shavings and one or two nicks in the white area of the bumper. That was caused by the dremel that was used to cut the bumper area behind the black insert to allow space for the DRL. If you get these shavings on your paint do NOT worry. They wipe right off with a microfiber towel and some cleaner as you can see in the finished pic.
It's also worth mentioning that during this process, your front end will look horribly damaged and you may wonder if you have ruined your car. Trust me, you haven't. As messy, damaged, and dodgy as the car looks, it WILL go back together and look brilliant when you've finished.
Part ONE: Lower bumper insert removal
As you can see, the lower bumper sort of intersects the black grille insert so that the black insert has an upper and lower section at one end, then becomes one piece as it reaches the fog lamp area. You will only need to unclip the lower half of the insert for this mod. It is clipped to the bumper rather tightly so you will need to use some brute force to yank it away from the bumper. The insert is more like rubber than hard plastic and is very flexible so do NOT worry about snapping it into pieces. I happen to have some plastic trim removal tools that can be wedged in between trim pieces and the the part they clip onto. If you don't, get some (LOL) or use a flat headed screw driver but make sure you heavily tape the bumper area where you will place the head of the screwdriver to avoid scratching the painted area around the insert.
When you get the insert to pry away from the bumper, get your fingers or a pry tool behind it and yank very abruptly to dislodge it. After it is free from the clamps, it will bend easily almost like rubber. You will need to cut the bottom of the insert to accommodate the height of DRL. Simple measurements are all that is needed.
The chrome bezel does not need to be removed, but turns out that when we bent the insert piece away from the bumper, it partially popped the bezel loose and it could be removed just by pulling it off with fingers.
Part TWO: Cutting the bumper
Notice the mess around the area where the DRL is placed. The bumper is a solid piece behind the insert. You will need to actually cut part of it out to allow depth for the DRL to fit back far enough not to stick out beyond the trim piece after re-installing it. Place the DRL onto the bumper so you can see how much of the inner bumper needs to be cut out. It will require drilling holes to allow you to get a very sharp knife, a small hacksaw, or other cutting device in position to make the necessary cuts. Remember, this area of the bumper will not show once the insert is re-installed, so do NOT worry if your cutting job is sloppy like mine. There is absolutely NOTHING behind this part of the bumper so do not worry that will cut a cooling line, the radiator, etc. We cut from the fog lamp all the way over to the opposite end, being careful NOT to cut the outer fascia of the bumper where the insert meets it. Luckily, the DRL is the perfect size to fill this area completely. Remember, any hot shavings that stick to the bumper will wipe right off after they cool, leaving no marks.
Part THREE: installing the DRL
I did not use the mounting hardware or frames supplied with the DRL kit. Instead I used professional grade 3M tape. You can get this at Home Depot in the paint department. It is marked clearly on the package as "20lb" tape. It is wider than the usual tape, has a more secure grip, and is water and temp proof. All of my DRLs were attached this way and they NEVER came loose due to temps or weather.
Before you actually mount the DRLs, do plenty of testing to ensure the grille insert will fit back into place with the DRL on the bumper. The DRL should line up with the re-installed insert piece and match the angle of the insert piece as well. Be careful NOT to cut too much off the bottom of the insert. You want it to re-install so that it drags over the the top of the DRL with no air space. Mine fit snug enough that even if I couldn't get the insert to clip at the top, it's snug enough against the DRL that it will not pop back out. In fact it is so snug that the DRL would probably not fall out even without the 3m tape.
After test fitting many times for placement of the DRL, make some marks along the bumper so you can line up the DRL at the proper angle and depth when you mount it. To mount it, have your assistant hold the insert piece bent away from the bumper. Apply 3M tape to the bottom of the DRL and position it according to the marks you made. Press it into place and push down to allow the tape to grab the bumper and mount securely. Then slide the insert back over the DRL and line up the clip at the top so it pops back into the bumper.
Re-installing the chrome bezel was tricky because it has multiple clips and guides that each has to fit properly to get it to click into place. Just be patient and feel free to curse during your many attempts to re-install it.
Hope this helps. We (Scooter really) made a couple of scratches on the fascia of the bumper which I will touch up. They are visible when viewed from an inch or so, but are not noticeable from any kind of distance. Just go slowly and be careful with your tools and if that means the better part of your afternoon to complete this, so be it.