2005 Grill conversion

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Jul 3, 2007 | 01:45 AM

Billinvancouver1

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2005 Grill conversion

Has any one cut down their own grill here, I know you can order one off ebay but I just got the new headlights and grill from a friends wrecked superduty. I just called defuser today and he was very helpful with this info on my project so I ordered the Harness from their site, I cant wait for it toget here. Also the chance to talk to some one for a few min that has done this conversion before was worth the 69.00 that the harness cost.

As far as the grill I was thinking that I would just lay my factory 2001 grill on top of the 2005 grill and trace the shape on the 2005 grill and then cut the basic shape out with an air saw, then fine tune it with a belt sander and a file..... any input would be great if you have a better idea.. Or a picture of the back of one of those ebay grills before install I would love to see how they did the lower mounts.

Jul 3, 2007 | 08:42 AM

pfb

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I needed a new grille, and wanted to add a 2005 grille on the cheap. My truck is a kind of scratched up work-truck, so a $300+ grille just wasn't in the cards... I bought an '05 grille off ebay for $50 shipped.

Here's how I fit the grille:

Remove the old grille
Hold the new grille to the opening. Take a sharpie and mark the areas that need to come off.
Dremel with diamond bit, hack off a long strip along the bottom that was clearly in the way.
Mark again, trim areas again, repeat till rough fit is o.k.
Take an angle grinder, smooth out the somewhat rough dremel cuts. It worked sort of like a planer on wood, smoothing everything out.
Test fit, grind high spots, repeat.

It sounds harder than it was. If you are a perfectionist, you will probably be better off buying the pre-modified grille, but I'm quite happy with my $50 '05 grille! I'll try and snap a picture today.

Jul 3, 2007 | 08:47 AM

RACERX7775

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Joined: Oct 2005

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From: WARRINGTON, PA

just remember, you will have to wire tie the bottom of the grill onto the header panel because the bottom clips wont even be close to being lined up.

Jul 3, 2007 | 09:26 AM

Billinvancouver1

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I'm going to give it a try I only paid 150 for the grill and head lights, so if it does not work out it still means I only paid 150 for a sweet set of head lights.

I would still like to see the back of one of the ebay grills if by chance some one took a picture before installing.

Jul 4, 2007 | 06:16 PM

barnbuoy

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From: hudson,florida

hey bill,

hows the front bumper on your buddy's truck??

i need an 05 bumper and surrounding stuff.

Jul 5, 2007 | 12:22 AM

Super Steve

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From: PHOENIX

check kingkustomstemecula.com
They did a write up on a conversion.

Jul 6, 2007 | 06:43 PM

Billinvancouver1

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I did the grill yesterday just cutting down the 2005 grill, Started with an air saw and then allot of time with the belt sander to get the shape right, 2 small zip ties at the bottom. No way would it be worth 299.99 to get this already done, just find a grill and mod it, there's grills on craigslist in portland for 150.00.

Next will be the head lights I got the harness from defuser today. I want to go out and put them on now but its very hot out. I think I'll wait until sunday the temp should drop by then, I did not get the defuser hardware kit I'm thinking I will not need it, we'll see.

Also to answer your question the bumper was damaged just the lights and grill were good