Cracked Bumper fix and 04 Headlamp Conversion
 

I finally got around to this project. I've had the headlamps for a while, I was just debating on an HD front bumper, or an 03 or 04 bumper cover. When out of no where I stumble on the deal of the century and bought a 2001 front bumper complete with all hardware and fog lamps, for $50! So that solved that.

It did have one hole punched out in a corner so I actually bondo'd that, painted black, then added the chawton white to the fog lamp areas. Once the bumper was complete I tackled the headlamp upgrade today and it was much easier than I thought it would be. Although, I did have to break into the first aid kit a couple of times, there are some tight areas to be cutting in with a sawzall.

It's difficult to do a step by step write up on the headlamps because of the variables but these series of photos should be enough of a guide.

What I started with:

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Bought for $50

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That looks really nice. Great work. I love the 03/04 headlights. They look awesome.

And I was happy about installing a bolt/wing nut to secure my battery cover. Great Job!

Looks really good. Those headlights go better with the old style bumper better than I thought. I might actually prefer it like that with the older grill and bumper. Nice job with the bondo too.

I actually think the combination that you have looks better than the normal 03/04 look. Very good job!

Awesome work Andrew! That came out perfect. While it does take some time to do it the right way, it's definitely worth every minute!

Looks great. This project is definitely on my to-do list. You made it look really easy.

I see you have two screws securing the top of the housing. What secures the bottom of the headlight housing in place?

Here's a picture Zach sent me:

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This is the underside of the headlamp trim piece. You can get to this screw from the wheel well. In this picture Zach used a nut and bolt to secure the new lamp at the bottom. I used a larger wood screw as the trim piece and headlamp are plastic, it worked well. With that one connection on the bottom and the two connections on top, the lights don't move at all.

And thanks again Zach for all of the emails and instructions! I wasn't planning on this combo of old and new but it turned out pretty well!

No problem! Glad it worked out for you, I'm definitely happier with my truck after doing this. The old style just looks....old haha.