BEFORE YOU BEGIN
The JK Brawler Lite Skid is shipped un-painted. Before you paint or powder coat, perform the entire installation of the product to ensure that it fits without risking damage to your paint or powder coat finish. Poison Spyder Customs is not responsible for paint or powder coat costs in the event you damage the finish during installation, or that the parts are incorrect or defective.
You will want to paint or powder-coat these components prior to FINAL installation. If painting them yourself, we recommend starting with a quality etching primer and allowing sufficient cure/dry time between coats and before you apply color. Quality spray-can paints are fine, however be sure to thoroughly paint all of the inside corners and hard-to-reach areas of the bumper. A little extra time and attention to detail on your preparation and paint process will pay off in longer-lasting good looks and rust prevention.
The following installation instructions assume that the customer already has a Brawler Lite or front bumper, and that the OE bumper or the Brawler Lite bumper has already been removed from the Jeep. See the instructions that came with your Brawler Lite front bumper for details on that procedure.
1. Park vehicle on a level surface and set the emergency brake. You will want to wear eye protection beyond this point. It is assumed the stock bumper has already been removed, and that the Brawler Lite bumper installation is already in progress (The bumper shuold not be mounted on to the Jeep yet). Perform the following steps for installing the Skid Plate, within the bumper installation procedure where noted in the instructions for the bumper.
2. Bolt the Skid Plate to the bottom of the Brawler Lite Front Bumper, using the nine (9) provided 3/8-16X1 Gr8 Hex Head Cap Screws through the holes in the mounting flange for each piece, fastened with the provided 3/8 Gr8 Flat Washers and 3/8-16 Gr8 Nylon Insert Lock Nuts. These holes will align when the two pieces are properly mated together. Note that the bolts at the front-outermost corners on each side may interfere with the Jeep's bumper mount flanges. This is due to some year-to-year manufacturing variances in Jeep models. If yours does not fit properly during test fitting, simply pull the bumper/skid, remove the two front-outer bolts, and continue with the installation. Deletion of these two bolts will be insignificant to the integrity of the bumper/skid structure. Tighten the 3/8" bolts.
NOTE: The factory "crash bar" is the thin sheetmetal crossmember which runs from one side to the other, at the front of the Jeep's frame, just behind the bumper (the bumper should already be removed at this point). There is some small interference between the crash bar and the skid plate, the amount of which will vary by Jeep year model. At your discretion you may choose to either trim the crash bar to accomodate the skid plate, or remove the crash bar altogether. We recommend complete removal of the crahs bar. The crash bar's purpose is superficial once the skid plate is installed, so it may be removed without any compromise of the Jeep's structural integrity.
3. If the choice is made to REMOVE the crash bar, use a pneumatic cut-off wheel to simply cut the crash bar and its side bracketry completely off of the frame. Clean up the cuts with a grinder, and paint the bare metal to discourage rust. Skip this step and move to the next step if the choice is made to keep the crash bar.
4. If the choice is made to KEEP the crash bar, the lower corner of the crash bar at either end must be trimmed for proper fitment of the Brawler Lite Skid Plate. Use an abrasive cut-off wheel or other suitable cutting tool to trim off the end of the crash bar. On most year models, your cut should be adjacent to the outside edge of the front vertical support, or 7/8" inboard from the outside edge of the outermost frame bracket as shown in Figure 1. Due to variances in different year models, your JK may require more or less trimming than shown. So some test-fitting and further trimming of the crash bar may be required.