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For those of you that have done this, what works best for cutting the header panel? I was going to use a sawzall with a bimetallic blade but am concerned about splintering. Isn't the panel fiberglass? Oh well what worked best for you?
I went with a new 05 header panel. I regret it. It is plastic, not fiberglass and weaker. In fact, it arrived broken. Even when I got it in, the right headlight (which is OEM) doesnt quite fit right. I have read there is a piece I need to trim but I cant find out what.
Point is, I wish I had cut my old one. So stick with that plan.
I have not done this because I have an 06.
BUT if you have a choice I recommend the relay option
for the headlights. You will have a brighter light because
you would have the loss from the smaller line and the splices.
Just make sure if you brew your own that you put fuses in the
lines.
Here is a handy PDF. It't the Ford Pigtail catalog with color images of the plugs. http://www.fordtechservice.dealercon...torcatalog.pdf
I keep a copy of this PFD on my computer. It comes in very handy.