Just have to get the top half right first.
Front end issues
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Lead Driver
Joined: Nov 2012
Posts: 8,304
Likes: 28
From: Salem, VA
Well onto another issue, the hood and grille gap. The header panel is only held on by 4 bolts, 2 on each side. Is that right? I can lift it (It's pretty flexible) about half an inch and the hood and grille line up perfect. Am I missing screws or what?!?
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Lead Driver
Joined: Nov 2012
Posts: 8,304
Likes: 28
From: Salem, VA
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Postmaster
Joined: Aug 2012
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From: Westfield, Indiana
Well been kind of MIA for the last week with work. But I installed and O5 grill on mine no fitment issues whatsoever bolted right up no gaps also replaced headlights but mine are Eagle Eye lights.
Senior User
Joined: Jan 2011
Posts: 277
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From: Midwest
Bumper problem - the plastics on your bumper were designed to go with a larger fender flare. Chances are the Super Duty had larger flares in 05, the 05 Excursion bumper is probably a one off to work with Ex flares.
Headlights/grill gap - the headlights look they are designed for the hood to sit lower than the fenders, but of course yours does not. they just don't look right. I would just fill that gap on each side with some plastic. As to the grill, you should be able to move the grill up a little where it mounts to the header. how is the gap between the grill and the bumper?
I hate to say this, but I don't think your header is square. It could be your truck has a little front end tweak from an accident, but more likely you are just not getting it sqaure installing it.
Headlights/grill gap - the headlights look they are designed for the hood to sit lower than the fenders, but of course yours does not. they just don't look right. I would just fill that gap on each side with some plastic. As to the grill, you should be able to move the grill up a little where it mounts to the header. how is the gap between the grill and the bumper?
I hate to say this, but I don't think your header is square. It could be your truck has a little front end tweak from an accident, but more likely you are just not getting it sqaure installing it.