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Long story short after cutting I find the fiberglass looks too flimsy.
I remember when I cut mine and it looked flimsy too... that was 8 years ago, and I've not had a single issue. If you followed the directions and cut where it said, it will be fine. Just becuase it looks flimsy does not mean that it actually is, and that it won't hold the headlights solidly. Bolt in the headlights and see how they fit & hold before you spend time & money on a fix that may not be needed.
I believe the header goes lower where the lower part of the grille goes on the 05-07 header to accommodate the taller grill. So unless you change the bumper you may have grille fitment issues to address
Correct. I just did a '05-'07 header panel + grill on my '01 EX and the bumper needs to be replaced because they hit each other. There is about 1.5" of overlap. A custom-built bumper is in process. For the mean time, I built spacers to space out the bumper about 2" from the original position so it may be driven.
Everything should be fine, if you want you can get the 05-07 header panel, all you would need at that point is the adapters required to use the H11 (I think?) bulbs with the 9006 harness, I am planing on doing the same for my Mustang with projection refit as well
Everything should be fine, if you want you can get the 05-07 header panel, all you would need at that point is the adapters required to use the H11 (I think?) bulbs with the 9006 harness, I am planing on doing the same for my Mustang with projection refit as well
For my 2002 Excursion updated to 2005 front end and lights, I used these adapters:
Correct. I just did a '05-'07 header panel + grill on my '01 EX and the bumper needs to be replaced because they hit each other. There is about 1.5" of overlap. A custom-built bumper is in process. For the mean time, I built spacers to space out the bumper about 2" from the original position so it may be driven.
That is unfortunate. Is the bumper different, grill or both?
That is unfortunate. Is the bumper different, grill or both?
Both I believe. The grill is lower and the bumper is notched for the grill to fit.
I was just looking to see what it would take to put 05+ headlights on my 04 Ex. The newer grill would be nice but a new header panel and new bumper would be required as well unless you go with a modified/shortened grill? Header panel might still be required.
Is there a good HID conversion headlight that replaces the stock pre 05 (2 piece) units (w/o other modifications)?
Both I believe. The grill is lower and the bumper is notched for the grill to fit.
I was just looking to see what it would take to put 05+ headlights on my 04 Ex. The newer grill would be nice but a new header panel and new bumper would be required as well unless you go with a modified/shortened grill? Header panel might still be required.
Is there a good HID conversion headlight that replaces the stock pre 05 (2 piece) units (w/o other modifications)?
I went with the cuts in the '00 header panel route and the modified 05 grille while doing the headlight swap. I agree with the OP that it looks flimsy in certain places. It was also tough in my case to get the headlights to be aimed right. That's a long story ....
The best HID setup, IMO, would be a DIY using good components. I am a big proponent of the Morimoto projectors and HID kits sold by The Retrofit Source. I have bought 4 sets from them so far for different applications. Great products and excellent support from their Customer service. I have heard mixed reviews of the aftermarket stuff available on eBay or Amazon. Though it works well, I am not at all happy with my current HID setup on the EX. Working on a retrofit of a LED projector, along with a '15 front bumper mod. At some time later in the year, I will swap out the header panel from an 05 to get the full grille and also be able to completely line up the bumpers. Not the best angle for a picture, but here's where it stands for now. The fog lights are HIDs from TRS too.
I have no experience with Projectors or HID other than my 04 Navigator has the HID low beams and know you can not use HID for high beams as they are not instant on.
