After spending a couple hours with my design programs, measuring lights, going to Pep Boys and speaking with a few "creative" people at my primary job, here is what we came up with...
Our current light is 4". Everyone likes the look of this current size, rather than a big one due to the angling effect of the front lip. Otherwise, no lip, a bigger light looks good such as the P5.
You can NOT go bigger than 4.75" top bottom and 5" left right with a light set back as much as our 4".
If you move the light out 1" (looks okay before looking bad), then you can go 5 1/8" all the way around BUT that is the MAX. We picked up a set of different Pilot's that were 5 1/8" with a color ring around it. We mocked it up. Though, this still does not solve the trim problem.
You can STILL SEE the stock clip holes. A little less, but it still exists. The price would go up about $30.00 as well.
Back to the trim piece.
So, here is where we are at. We have a template and have successfully been able to cut it in sheet metal and plastic. It looks really nice, though we are in need of "someone" to take a template that we currently have, and mass-produce it in 1/8" plastic. My plastic supplier here (used to use a few years back) is out of business.
Does anyone know of a plastics company that can take a template, scan it in (to scale) and cut it?
Oh yeah, quick EDIT here...
We would be able to create a different bracket/mount to attach the fog light directly to this piece so all you would do is take the entire assembly, slide it into the big opening, drill, two holes and screw in. This is soooo much better and would have a "flush/molded" affect and would be around the same pricing as we currently offer.
- Brian