I was never happy with the looks of the 89 grille so when I got the truck painted I decided to update it with an aftermarket grille from a 92. The parts you will need are the grille, the 4 inserts, the headlight doors new left and right parking lights and the valance piece that goes across the bottom. I got the valance piece from Oliver.

Here'a a pic with the valence in place and the grille just hanging on the front.

 

I started by removing the headlight and the adjustable holder. Then I marked the base for cutting. If you use a plasma cutter or a torch be sure to protect the wiring behind it with a fiberglass mat or something non-flammable.

 

I used a jigsaw to cut out the base but I still hit the battery pan with it. There wasn't anything to hit on the right side.




I then cut a piece of 16 gauge sheet to fit the hole and welded it in. This left a nice flat place to attach the headlight in the new position.

 

I cut strips of 16 gauge sheet to 1-1/4 inch wide and welded them to the base I cut out.


You'll probably have to grind on it some to get it to fit where it needs to go.




By hanging the new grille with the headlight door in place and the headlight holder assembled as shown I was able to hold it in place while I marked it in it's new position. NOTE: the 1-1/4 inches places the base of the holder just about flush with the new flat surface of the radiator base.




You'll need to saw or cut out the opening for the base of the headlight to go through. I went ahead and cut mine out to full round hole to accommodate the HELLA lights with quartz halogen bulbs.

 

Repeat the process for the passenger side. Here's a pic of the grille hanging on with both headlights re positioned.



To hold the new grille at the bottom corners you'll need to fashion a piece to run a screw through the hole at the lower outside of the parking light hole to attach to the base behind. You'll also need to cut out the base to accommodate the new parking lights.

NOTE: The grille I got was rather fragile and the tabs that attach the top break off very easily Since it sort of hooks over the radiator this wasn't much of a problem.

 

Here it is nearly finished except for a bit of rattle paint for the valance.




I'll be happy to answer any questions about the job. I also tried to find the sticky that disappeared but I decided to go it alone.

Edwin

 

Nice post.
Thanks Edwin!

 

Well done!!

 

Many Thanks Edwin
This should be a sticky!