Editing Z31/Frontendconversion php (section)

=== Headlamp Fitment ===

From what I've read, the headlamp buckets should simply require drilling a couple of new holes and bending the base of the bucket. For some (perhaps '86 model year), this is the case. Unfortunately, for me, it was substantially more involved—but the result looks factory.

Here is a side-by-side comparison of the '87 and '84 style headlamp buckets. They are laying headlamps down—the '87 is on the left. Notice the '87 bucket is substantially deeper than the '84.

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp1.jpg

As you might guess, when the '87 headlamps are installed on the '84, they won't recess—the '84 bucket is not deep enough to accept the '87 assembly.

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp2.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp3.jpg

To fit the '87 headlamp, the front metal piece must be removed. Based on the height the headlamp stuck up above the hood, approximately 3" of material had to be cut out. I used a 4 1/2" angle grinder with a 36-grit cutoff wheel—disheartening, but necessary!

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp4marked.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp4.jpg

The '87 headlamp mounts to the car differently than the '84. There are two studs on the bottom of the headlamp that mount through the bottom of the bucket. These must be drilled out to fit the '87 headlamp. To do this, I painted the studs with fluorescent paint and installed them, then drilled holes where the paint marked.

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp5.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp6.jpg

I had to drill a couple of holes to get the left stud to line up. Additionally, I had to elongate the holes until everything adjusted correctly.

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp12.jpg

The '84 headlamp bucket is too deep on the inner edge, causing the headlamp to tilt toward the radiator. To fix this, the bottom of the bucket must be bent upward by approximately 1–2". I used a body hammer with good results.

Once the holes were drilled and the bucket bent, I test fit the headlamp. The brackets that mount the bucket to the radiator support were too short—the bucket stood about 1/2" above the hood. To fix this, I cut off the brackets with the angle grinder and welded on replacements from 1/8" mild steel.

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp7.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp8.jpg

With everything modified, I then spent about 2 hours bending, tweaking, and adjusting to get the headlamp to sit flush and properly angled with the hood. When everything finally lined up, I tack welded spacers to each mounting point so the headlamp would align again when removed.

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp9.jpg

Once installed and aligned, I rebuilt the front metal piece using 22-gauge steel, moving it outward about 3/4" from the original. (The funky-looking black stuff is just a weird reflection.)

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp11.jpg

When everything fits as desired, brush all welds and seams with 3M's brushable seam sealer. Re-undercoat the base of the bucket and repaint the radiator support panel, bucket sides, and new bucket frame to match the underhood black.

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/headbucketfin2.jpg

And the final results: This took me about 4 hours nonstop. Hopefully, the passenger side will go even faster with the experience gained!

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp10.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/Raredare1/frontconversion/87headlamp13.jpg