I did this install back in November but haven't had a chance to post about it till now. I would like to thank all the members who contributed to this forum because it was great help. This actually was multiple installs in one: I got the ZL1 bumper, DIY harness, Curb Alert, and camaro2lt's idea of ZL1
bumper cold air intake ducting.
For the bumper, I contacted MaureenM@RodgersChevrolet, and she had a pre-painted ZL1 bumper. I took a risk and got lucky because the paint match was perfect. Specifically, I got:
#22831868 Fascia
#22895338 R Bezel
#22895339 L Bezel*
#22894223 Lower Grill*
#20952857 Support*
#20952853 Absorber
#20957334 DRL Retainer (you need 2)*
For the nuts and bolts, I refused to pay GM's prices and got replica parts with the same dimensions that worked just as well. For the bolts part #11570637 , I bought "
Phillips Pan Head Sems Tap Screw M4.2-1.41 X 20mm." For the nuts part # 11610157, I bought "
Nut With Silicone Pad." The only thing I got from GM were the plastic rivets (# 92231490) and two clips*(#11562364) because they weren't expensive.
For the upper fog lights, I got 2007-2012 Chevy Avalanche/Tahoe fog lights (same as Camaro's) off ebay, which house Putco Pure Jet Yellow 3000k 9009/H16 bulbs. I had to modify ZL1 DRL retainers to hold the lights by cutting off the top part of my LS retainer, where the adjust arm would sit, and using some plastic weld epoxy to add it to the ZL1 retainer.
I got the lower fog lights off
amazon, and used 6000k H11 7w LED lights (match my 6000k EE halos).
Making the harness was the most challenging part but was fun because it forced me to relearn the basics of electricity physics and circuit design. Also, because I have an LS, I had no pre-wiring for fog lights and I wanted to be able to control each set through in-dash toggle switches. The most important things are to figure out the amperage, correct wire gauge, fuse sizes, and select the right power sources. It also involves a lot of splicing and connecting (through crimps and liquid electrical tape), and you need the right wire pigtails for the bulbs, but I integrated everything into one harness by using a wire loom.
(wires before loom)
The Curb Alert system, LED fog lights and LED indicators on the toggle switches, which all draw little power, are all connected by an dd-a-circuit plugged into slot F18 in the driver side fuse box. The halogen upper fog lights are rated at about 37 watts so I connected those to the battery through a $10
ebay relay, with the trigger coming from the F18 fuse going through one of the toggle switches. By the way, the F18 fuse is an ignition fuse, so the power goes out when the key is removed, which will protect the battery if you leave the switches on the "on" position.
Lastly, since Virginia requires front plates and I didn't want to ruin the fascia, I didn't like the off-the-shelf solutions, I decided to cut off the bottom on the plate and installed it in the lower grill. I cushioned the back of the plate and held it with long bolts and padded washers.
It's been six months and the harness has held up through winter with no problems.
