It seemed too simple and, in fact, it was!
When the parts manager at a local Dodge dealership suggested we update the look of Project D150 with the '91-'93 Ram grille, we really like the idea. That was, until we realized that the conversion would require an entire radiator core support due to the outward positioning of the headlamps and their higher orientation in the '91-'93 grille. Since we jumped to conclusions and assumed all was the same for the D150s, we had already acquired the aesthetic parts from Sherman & Associates. That predicament forced us to call Terry Thompson of Thompson Auto Body to evaluate our radiator core-support dilemma. The question for Terry was, "Would it be less-involved and cheaper to fabricate modifications to the existing core support or should we go out and locate a salvage-yard '91-'93 core support?"
To ensure a proper fit, the...
To ensure a proper fit, the first step was to assemble the beauty ring on the grill so the measurements would be correct. Here, Terry, from Thompson's Auto Body, makes score marks in preparation for cutting the radiator core support based on the initial beauty ring positioning.
Thankfully, Terry reported back to us that the unseen part would continue to be unnoticed with some creative work with a pair of welders--a fire axe to cut it apart and a MIG to piece it all back together. Despite the struggle with the grille, the installation of AAR Fiberglass Reproductions Dodge R/T hood was straightforward and simple. Jeff Thompson (no relation to Terry) accommodated us by applying the Viper Blue topcoat to match the D150 and handled the installation of the hood.
As it turned out, the phone call ended up being the simplest thing about installing a '93 grill on an '87 truck. Little did we know how much was involved. It bolted on without any problem, but the headlights didn't line up. If we wanted this to work we had two choices--install a new '93 radiator core support or cut and weld. The core support was over $700 from the Dodge dealer, and we couldn't find a good used one, so Terry Thompson convinced us to modify the existing core support. Follow along and see how we made out.
With an angle cutter Terry...
With an angle cutter Terry cuts a square around the headlight mounting area of the radiator core support.
Terry removes the sheetmetal...
Terry removes the sheetmetal square so it can be relocated on the radiator core support to a position that will center the headlamp correctly in the grille.
A grinder is used to clean...
A grinder is used to clean paint away to create a good surface for welding.
A piece of 1-inch angle is...
A piece of 1-inch angle is tacked onto the removed square.
The new location for the headlight...
The new location for the headlight is one inch forward of the original position in the radiator core support and two inches higher. Here, the headlight mount is welded in place. The top and inside receives a 90-degree angle so that the headlight adjusting screws have clearance. The bottom and inside receive 1-inch square tubing for better stability.
This is the original location...
This is the original location of the headlight mounting bracket.
And here's the new locati...
And here's the new location.
Terry cleans off the rough...
Terry cleans off the rough edges and applies a fresh coat of paint. Note the area under the headlight opening. This small square is removed to create clearance for the wiring to the parking light.
After mounting the grille...
After mounting the grille frame, the parking lights are put into place.
To complete the grille assembly,...
To complete the grille assembly, we install the grill inserts.