Headlight Grilles - Bar Style

I have installed a couple of different types of grills. I prefer the bar grills. I had no problem installing either one of them.🤷‍♂️

I think I got it late last night. I actually ended up leaving the grilles “installed” a bit wonky, then parked the car in a warmer part of the garage. The gaskets softened up a bit by the morning; all formed into place. I’ve never had a gasket be so thick and stiff.

@IndianBob Wom womp. Hit a snag. What did you do to connect to the fender. The hardware that comes with the grilles is too short to make it through the fender to the nut. Did you bend the bottom bracket of the grille?

I bought mine from Aircooled Accessories, a UK outfit, and they fit right on and didn't require removal of the glass lense on the headlight.

Makes sense. I really liked the straighter lines of SMC ones. For the near-term solution, I’m toying with the idea of just purchasing new, albeit less attractive, hardware. I can always engineer something better in the long-term.

Get a metric tee nut and insert it through a hole from inside the fender.

Use the kinds without the prongs.

Then your hardware will be long enough.

AMAZING!!!!! Thanks, Mike!

I also use a nylon spacer on the bolt so I don't bend the tab on the grille.

Call me crazy but it seems kinda dumb to replace the glass with a grill, especially if you ever drive in the rain. I guess if you use sealed beams it’s no big deal, but I’d rather not risk my $50 Hella H4 lenses.

Agreed. I don't drive in the rain. Full disclosure: I live in a high-rise in downtown Washington, DC. I have absolutely no need for a car. This is my escape - literally and figuratively - from my clients when my head is about to explode. The grilles are an aesthetic choice that I've loved since I was a kid. 

I like the look of the grilles. I was bothered by bugs getting through and dying in the headlights.

I found some plastic pieces that are formed to fit behind the grille.

Me, too.

Pro tip: Spray em with WD-40, turn on lights. Pressure spray car wash starting at the back. By the time you get to the headlight, the bugs will fly right off, so to speak.

@JoelP posted:

@IndianBob Wom womp. Hit a snag. What did you do to connect to the fender. The hardware that comes with the grilles is too short to make it through the fender to the nut. Did you bend the bottom bracket of the grille?

joel. My bar grills don’t have a gasket. I just clipped them on the beauty ring of the headline and screwed in the bottom tab. Was I supposed l to take the glass off.?

Update: found the driver side fiberglass was laid quite thick below the headlight; hence, the fastening nut is actually buried in the fiberglass a bit. Therefore, I'm going to have to thin it to a manageable thickness to get my metric tree nut in on that side.

I was going to say that this was a "troublesome" update, but I'm finding that these obstacles are making this all kind of fun. That said, going forward, I will be posting pics as I move along for others' benefit.

Thanks to all for your help and insight thus far. I sincerely appreciate it.

Top pic is driver side, bottom pic is passenger side.

It looks like you used hex nuts, not tee-nuts.

They extend into the fiberglass and only the round flange is on the surface.

That's not my work. That's the "before" picture. I didn't want to get hardware that I wasn't sure would fit without first investigating the condition of the fiberglass. When I saw the thickness, I knew there was way more work to be done than a simple hardware swap. I want the surface to be flat so the t-nut can be inserted easily. Just being overly cautious because I have the luxury to be so.

Looks like you might need to grind the t-nut flat on one side to fit up against that angle. If it were me, I’d find some fiberglass-compatible adhesive and once everything was trial fit to my satisfaction, I’d slather up the flange prior to putting it all together (taking care not to let any get on the threads) then let it set up with everything tightened down.

I love Wurth PowerBond, but I already have it. In between the adhesive, the applicator, and the tips, it’s a bit of overkill for two T-nuts. Maybe check the Permatex site for a compatible adhesive. I think any “non-hardening” adhesive like Gorilla Snot (3M Weatherstrip Adhesive) would work as well.

One of my most treasured tools is a 3/4" ball rasp with a 1/4" shank I use on thick fiberglass for taillight, signal light, headlight screws and rocker Deco strip screws. I use it to make a cup in the back side of the fiberglass, going slow assures you don't go too deep.   

Drill America SD-7 Carbide Burr/Rotary File Ball-End Double Cut for Die Grinder 3/4" Dia. x 11/16" Cut Length with 1/4" Shank and 2-7/16" Overall Length, DUL Series: Amazon.com: Industrial & Scientific