Alright boyz and girlz I'm starting this thread so we can talk about the McNasty Customs kit installation details and front end conversion details in general.

I started the conversion build this weekend on my 2002 XLT 4x4. It took a few months to collect the parts, used and new.

For reference here are two other good build threads.

- Rob has an extensive parts list and discussion here: https://www.ford-trucks.com/forums/1...l#post16208393

-Ryan's Excursion thread is here: https://www.ford-trucks.com/forums/1...l#post16208393

Rather then muck those threads up, I started this new thread.

Here are a few random thoughts on the conversion for inexperienced, non-fabricators like me. Feel free to chime.

 

Alright, please post pictures as well.

 

You beat me to it bro.

Here is where Im at after 2 very long days of toil.

 

DUDE!!!


keep us posted with lots of pics!

 

Here are some random thoughts:

Get some body clip removers. Way better than scratching up your truck and removal is faster.

 

Tip: If you buy the McNasty bumper kit, which I think is worth the money, install that first after you've removed the original grill. It will help you know how far down to set the McNasty Grill brackets for the new grill.

Also, my kit only came with 6 17mm? bolts and nuts. I ASSUME these are for the ends of this bumper attachment arms. Three on each side. See here:




And from underneath:




The problem is that my original bumpers were only held on the front frame rails with 2 bolts on each side, 4 total and you need 8 bolts total to hold McNashhhtty's front plates to the newly cut frame rails and the new bumper. The bolts that come with the truck are through-bolts. They enter a 4 inch bracket with nuts welded to them. Youll need to cut one of the brackets in half to use the bolts. Youll see why the bracket cant be used when you get to it. And then you'll be short 4 bolts for the other frame-rail-end-to-bumper attachment. So buy 4 more Ford or generic 17mm nuts to match.

Here is the McNashtyness plate for placing the bumper lower and the McSashta "L plates" to box in the frame rails after they are cute. In his video he shows the L plates facing the other way but the 2 front bolt holes for the front tow hook bolts don't line up and actually you couldn't install the tow hooks with the L plate anyway. Or wait maybe I can install them underneath the frame rail...not sure.






As an aside, I find the quality of the McNasty components to noteworthy. His instructions however are a C+. His videos are very helpful but also very generic. I know he is trying to appeal to other fabricators...but still. I bet he would sell a lot more kits if his instructions were better.

 

The templates leave a little to be desired because they don't exactly conform to the curved body of the truck. They also have an area on the extreme left and right which is marked as needing to be cut but which doesn't make any sense. Maybe its for the 2003-2008 trucks?

In my case I simply taped, cut out with razor and then marked with sharpie then cut with 4 inch wheel. My air grinder took a crap on me so I borrowed a friends 4 inch grinder with a 5 inch cutting disc and 4 inch grinding disc to help with sharp edges.

Like this but no side handle and no safety guard on it (buy a $13 face shield at Home Depot!!!!!!).








I think an air grinder with 3 inch disk would have been way too slow. Its a lot of metal to cut especially the frame rails. I ended up using 3 cutting discs and used the grinding disc a little and metal file to get rid of the razor sharp edges.











I dont think it matters much if you cut an larger opening as long as you arent left without any metal to affix the new grill brackets to the body.





Then the trimmed 2015 OEM lower support bracket is attached to the bottom of the grill brackets. The distance between this bracket and the upper bracket (not shown) is dictated by the grill itself.

Note that I didnt use ANY Nutserts (u need a M6 adapter for the Nuserts that come with the kit, which comes with the Astro tool 1427) to this point. Its all held in place with self taping screws supplied in the kit until I have the body panels mocked up.

 

As for cutting the frame rails. I removed the passenger side tow hook for cutting blade clearance reasons. I probably could have left it in place. The driver's side rail I cut without removing the tow hook but I did nick the bolts a little in the process. The 4 1/2 inch cutting disc doesnt reach far enough to finish the job so I had to use a sawzall with bimetal blade to finish the job.

Before cutting:



After cutting (note that on the McNasty plate, the bolts on the left side would be places one hole down each. Thats the point of the plate. It allows you to place the 2015 bumper lower on the frame to accommodate the larger grill):

 

The wiper arms:

This retrofit is easy. McNashtyiness has a good video on it.


However I worry about how strong the union is at the motor once youve re-keyed the hole. Rob has a nice discussion about this: https://www.ford-trucks.com/forums/1...5-build-5.html on page 5.

I rekeyed the hole in the OEM pivot arm but I think its safer to tack weld it. I used some JB WELD 2 part apoxy to fill in the tiny spaces, but Im dubious. You dont want your wiper arms failing.

 

subscribing.

 

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Awesome job, Lex! Been eyeing the 08-10 conversion for over a year but here on clist, people are proud of their front clips, to sell off

 

Thanks Timmyboy. Im sorry I dont understand your point about the front clips.

Hey Rob, Ryan...feel free to chime in. This thread is a free-for-all.

 

People selling the fenders, grill, hood..etc, will refer to "all" being the front clip. Best price I found was 1800.00, including lights. I just can't spend that right now

 

Thats about what it costs new but unpainted. Youll have to paint to match anyway. Its about $3000-4000, parts and paint with your labor.