Spartan7
12-15-2012, 06:28 PM
The headlight panel, also called a header panel, is that black plastic bracket that both your headlights and front bumper mount to. It's not particularly strong, and is prone to cracking or shattering in mild accidents. GM replacements are ridiculously expensive, even used ones on ebay go for quite a bit. I scoured the junkyards for months trying to find one in one piece. Not only are LT1 'Birds seemingly rare around here, every single one I've found had a damaged one.
So I turned to an aftermarket reproduction. You can find these on ebay for around $100. Just buy the cheapest one, they all come from Taiwan. Of course I was worried about it, knowing the reputation of aftermarket body panels. However, this seemed like a fairly accurate copy.
This is what arrived. It came with all the metal mounting brackets.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2544.jpg
Here is the side by side comparison next to my very trashed original. Long story how it got this way.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2546.jpg
In further examination and mock-up, I was not happy with the quality or fitment of the metal mounting brackets supplied, so I reused my stock brackets. Mounting and alignment turned out fairly well, except for one thing. The little metal ears that the headlights mount to were so tweaked and misaligned on the repro. brackets that it would take forever to get them right and the headlights aligned correctly.
They are simply attached to the plastic by rivets. So I drilled them out on the original to reuse those brackets. Just a note, only 3 hold it on. The fourth is only for the headlight travel limiting cable, no need to drill it out!
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2549.jpg
Here is the bracket off the plastic panel.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2548.jpg
Of course, I had to drill the brackets off the new panel. They are only held in my pop rivets, just drill the heads off.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2550.jpg
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2551.jpg
Using 3/16" rivets and some rivet washers, I attached the OEM brackets to the new plastic repro. panel.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2553.jpg
All that was needed was to reinstall it. With all the mounting bolts loose, it pretty much aligns itself, and you can tighten everything after that. Then simply reinstall the headlights, bumper, etc.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2555.jpg
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2556.jpg
Overall, I'm pleased with how it came out, and it was a much cheaper alternative than an original. It also helped move my project right along, and I can finally finish up the front end. :D So if you've got a broken one, maybe this will help.
So I turned to an aftermarket reproduction. You can find these on ebay for around $100. Just buy the cheapest one, they all come from Taiwan. Of course I was worried about it, knowing the reputation of aftermarket body panels. However, this seemed like a fairly accurate copy.
This is what arrived. It came with all the metal mounting brackets.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2544.jpg
Here is the side by side comparison next to my very trashed original. Long story how it got this way.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2546.jpg
In further examination and mock-up, I was not happy with the quality or fitment of the metal mounting brackets supplied, so I reused my stock brackets. Mounting and alignment turned out fairly well, except for one thing. The little metal ears that the headlights mount to were so tweaked and misaligned on the repro. brackets that it would take forever to get them right and the headlights aligned correctly.
They are simply attached to the plastic by rivets. So I drilled them out on the original to reuse those brackets. Just a note, only 3 hold it on. The fourth is only for the headlight travel limiting cable, no need to drill it out!
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2549.jpg
Here is the bracket off the plastic panel.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2548.jpg
Of course, I had to drill the brackets off the new panel. They are only held in my pop rivets, just drill the heads off.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2550.jpg
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2551.jpg
Using 3/16" rivets and some rivet washers, I attached the OEM brackets to the new plastic repro. panel.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2553.jpg
All that was needed was to reinstall it. With all the mounting bolts loose, it pretty much aligns itself, and you can tighten everything after that. Then simply reinstall the headlights, bumper, etc.
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2555.jpg
http://i238.photobucket.com/albums/ff114/malomanm/Firebird/IMG_2556.jpg
Overall, I'm pleased with how it came out, and it was a much cheaper alternative than an original. It also helped move my project right along, and I can finally finish up the front end. :D So if you've got a broken one, maybe this will help.