just trying to see what you guys tihink. i am going to install some extra led reverse lights into my rugged ridge rear bumper. i have an angel grander but im not sure i wanna risk messing up. the lights are rectangular, bout 6 inches wide and 1.5 inches tall. any suggestions?

 

Reciprocating saw works great.

 

Drill a pilot hole with a large drill bit in each corner of the outline and cut away.

 

I would drill a hole at all 4 corners, then using a cut off wheel on the grinder cut out the main part, finish the corners with a file.

 

See if a local shop has a CNC or similar Plasma burner, and if they will do it on the cheap. My local shop charged 15 bucks to burn a 1/4" plate for me. Usually a dollar a minute... AND the precision cannot be beat.
If you are going to DIY, I would suggest corner drilling, then CHAIN drilling in a line, then connect the dots with the cutoff wheel, otherwise you are going to use a ton of wheels. If the bumper is 3/16" to 1/4", you could chain drill, then use a jig saw with a metal cutting blade to connect your holes, then finish grind.

 

Tape off the cut and hit it with an angle grinder and cut-off wheel.

 

x2

Actually, the real answer to the "best" option is a plasma cutter. But I'm assuming that if you had one of those, you wouldn't be asking this question to begin with.

 

definite x2 on the Plasma Cutter. We put in a Poison Spyder bumper on a buddy's JK a few weeks ago and started with the sawzall first, but when the plasma cutter showed up, it was WAY cleaner and easier.

So, if you've got access to one, I'd definitely go for it.