Modified Nova Rear Bumper
DISCLAIMER: The information on these modifications are a collection from experience (myself or friends), magazine articles, mailing lists, internet web sites etc. So don't take these as 100% correct gospel, hence I don't take any responsibility for any of these guides.

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Difficulty: 3/5 - Very time consuming

Click on any of the pics
for a large view.


Before...
Before...

..and after.
...and after.

This is a step-by-step guide on fitting the Peugeot 206 fog light into a Nova rear bumper. Now this may not be to every one's liking but I thought I try it out as I haven't seen done before (at the time of writing). This modification is part of the Euro Cluster conversion guide which takes away the fog light in the Nova cluster. So to finish of this modification and get the Peugeot 206 fog light to work, the wiring needs to be followed in the Euro light conversion.

It's seems to be an easy modification to do, offer up the fog light, draw shape, cut hole and wire it up. Wrong! When I got down to it, it took me four weeks to finish. The main problem was that the fog light had to go through both the plastic bumper and the metal carriage bar behind it. This is where an electric jig saw and tank cutter comes in handy. One thing to note is this will work with any model of Nova. This modification was carried out on a Nova GTE.

This guide also shows you how to smooth out the rear bumper. This is optional but of course the bumper needs to be resprayed afterwards. It is possible to carry out this job without spraying the bumper, you'll just have to be careful when using the jig saw and files (i.e. don't cut too far).


PARTS
COST
Various metal files Stanley knife for trimming Peugeot 206 fog lamp £13
Can of WD40 Wet & Dry (P100 to P400) Tank cutter - 20mm £7
Socket Set (metric) P38 to fill up grooves Tank Cutter adapter £8
Hammer Peugeot 206 Fog lamp Tub of P38 body filler £9
Tank Cutter & adapter Spare Jig Saw blades The part number for the Peugeot 206 fog lamp is 6351K5. The tank cutter needs an adapter to fit onto your drill. You'll also need some bullet connectors and a crimper to tap off the fog light signal off onto the fog lamp in the bumper.
Electric Jig Saw Mains Electric Drill
Mains Electric Drill Haynes book (very useful)
Crimper Various bullet connectors
Hand pad saw Sanding block

Just before you start, make sure you note the following:

  • Viewing where abouts the fog lamp will be on the bumper is difficult because your controlled by the amount of room you have in the metal carriage bar. Fortunately it works out to be in the middle and on the flat surface on the plastic bumper.
  • Separating the metal carriage bar from the plastic bumper can be a pig. It will involve a lot of bending of the plastic clips. Just don't bend them too far because they won't hold the bar back on again. I used a pair of pliers and a few screw drivers to prise it off.
  • You'll need a lot of patience with this as it can get VERY tedious when doing the cutting and filling getting the fog lamp to fit. Then you have to do it all again on the plastic bumper filling in the 3 grooves. In fact his took the longest time on getting it smooth.
  • Remember you can only cut once, so take your time and make sure you get the fog lamp straight and level. Mine is just at a slight angle, but fortunately you can hardly notice it.
  • When using the tank cutter, don't be surprised if it gets very hot and it starts to smoke and sparks are flying. Keep the bit cool by putting a few drops of oil on the metal work. The tank cutter will also last longer that way.
  • You'll also go through a few jig saw blades as well because the metal carriage bar is very thick.
  • When filling in the groves on the rear bumper, use small quantities and fill it up so that it just overflows in the grooves and stops air bubbles forming. This will give you less time on sanding it down.
  • When sanding down the filler, use rough P100 first just to get the main work down. Then move onto P240 and then finally use P400. Both of these work better when there used with water.

OK, got all the above? Then follow the steps below (remember to click on the pics for a bigger view):


Step 1 Step 2 Step 3
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The Pug 206 fog lamp will clip in the rear bumper from the outside. For this to do so, the lump on the clip needs cutting off (as shown)

Nut cut off the two little lugs on the bottom of the fog light. This is all the preparation needed on the fog light.

With that done, you need to make a template of the fog light so you know what shape to cut out on the bumper. Click on the pic above and print it out.
Step 4 Step 5 Step 6
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Take the rear bumper off (2 bolts) and look at the back of it. Place the fog lamp in the middle of the metal carriage bar. Once in place draw a rough line round the lamp. Just make sure it's in the middle.

Now you need to know where abouts the shape will come out on the bumper. So drill two holes of the outer most of the shape right through the metal and the plastic. Use the tank cutter for this. With the guide holes in, separate the metal carriage bar from the bumper. Place the cut out of the template on the metal bar and make sure that the lines drawn are in the middle.
Step 7 Step 8 Step 9
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With the lines drawn, use the tank cutter and jig saw to cut out the fog lamp shape. Always cut inside the lines and file finish. Turn the bumper over and remove the red stripe, by simply pulling it off. All three grooves around the bumper will be filled in at a later date. Line up the template to the two holes that were drilled previously. Draw the fog lamp shape on the bumper. Now use the tank cutter and jig saw to cut the shape out. Then file finish.
Step 10 Step 11 Step 12
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Keep on filing until the fog light 'just' fits in. This is the perfect size as the plastic clip should keep the unit in tension at all times and it won't fall out. Also make any adjustments to get the light level. With both the holes cut out in the bumper and metal carriage bar, it's time to fit these back together again. This might be tricky as the clips on the bumper are stubborn. Just use a lot of force and they should clip back in. Now fit the fog lamp back in and it should fit through both layers. It probably won't first time so some more filing and sanding maybe required. Again a tight fit is the best. Notice that the number plate light 'just' fits in.
Step 13 Step 14 Step 15
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With both the holes just right, it's time to fill in the 3 groves round the bumper. Sand down the bumper first, then use P38 to fill in the groves. Always use small amounts which avoids air bubbles. Keep on using small amounts of P38 and sand it down with P100 (rough). Then use wet and dry P400 to get a final finish. NOTE: this took me over a week to do by hand. Fit the fog light back in and pull off the two metal tabs on the unit (they're very tight). You can use the metal tabs to 'hold' the light in so that is doesn't fall out. Drill a small hole as shown above on both sides.
Step 16 Step 17 Step 18
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Now drill a small hole in each end of the tabs. Push the tabs back into the fog light and bend them so that the holes line up. The idea is to use a self taping screw to hold the tabs onto the metal bar. The two tabs on the number plate light unit need bending out the way. Try soldering two wires on the end, or if not use spade connectors and bend them such that it fits flush in the rear bumper. Fit the fog light and number plate light back on. Follow the Euro cluster guide to wire up the car for the fog light. Then bolt on the rear bumper as before. There shall be loads of clearance at the back of the fog light. Job done!

Not finished just yet.....

With the bumper on, all there needs to be done is get the rear bumper sprayed (not shown). Also make sure that the two wires that go into the fog lamp are long enough so when you remove the bumper, you don't strain the wires.

I mentioned above that the two metal tabs on the fog lamp could be used to hold the lamp into the bumper, so that it couldn't fall out. When I screwed the tabs on, the opposite happened at the fog lamp unit popped out. This is because the metal tabs were acting as a spring and was pushing it out all the time. Fortunately the hole cut was just tight enough in it's own right to hold the lamp in. So it's up to you if you want the use the tabs or not.

When putting in the fog lamp for the final time it might be wise to put some sealant around the fog lamp to hold it in there and to keep it water tight. Even with the fog lamp secured in, it does point down slightly towards the ground (very noticeable in the dark). There is enough of it pointing up level with the cars behind so this is OK with the MOT.


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