Replacing Headlight Assembly with Aftermarket Bumper?

[dresslered]

I am finally getting some time over the Holiday break to do a little catching up on my truck projects. One of the things on the list is to convert over to the Quad Headlamps. I now have an aftermarket bumper (Buckstop) and have noticed that after removing the three securing screws that I still cannot remove the headlight assembly from the fender. Is there a clearance issue with these aftermarket bumpers or am I just missing something? I really would hate to have to lower that bumper just to replace the headlight assemblies. TIA.

 

[Thomas]

Is it hitting the new bumper? Things look close in your gallery photo.



After disconnecting the electrical, pulling the pushpins in the welt, and removing the three bolts, it should pull forward. The only thing holding it with the items listed above removed will be the barbs on the plastic tangs. You can see the tangs on your replacement lamps. It may take a good yank.

 

[dresslered]

Thomas the headlight conversion guru! Thanks for the reply! Naturally, when I was replacing the bumper due to a very unlucky deer, I did not have the quad headlight assemblies at the time, and just figured that I would be able to replace them when all the pieces arrived. I left precisely the same gap between the bumper and the headlight assembly as the original, but it seems to be hung up on something. The new bumper definitely sticks out much further so maybe this is the problem. I've started with the damaged assembly (deer damage) and it is crumbling in my hands as I try to wiggle it free. I definitely do not want to install the 'new' using this same method. As dinner time approached, I called it quits for the day but will resume tomorrow. We'll see if things have changed any tomorrow.



Do the headlight assemblies have to rotate downward (around the bumper) as they are removed?

 

[Thomas]

If my memory hasn't failed me, I think it is prettry much a straight pull to the front.

 

[krs]

You won't need much more clearance than you've got and can probably get it by some judicious jacking of each fender in it's turn. You don't risk bending anything if you go slowly and with care. All you'd want is to stretch the front mount a little - maybe 1/4" will do. Failing that you should be able to loosen your bumper mount bolts and monkey the bumper down in back enough to make the room. Once each fixture is in it's allotted place you'll be fine finishing the bolt -in without further movement of the fender or bumper except to put them back in place.

 

[dresslered]

Sorry, no can do! This has turned out to be the job from HELLo! I've had to completely unbolt the entire bumper and am in the process of moving it forward (350-lbs!). This is tougher than it sounds when you have a winch installed. Also, I used locktite on all the bolts. PIAA's even had to be removed (loosing the alignment) to loosen the bumper from the bracket. The Buckstop fits very snug when mounted, and doesn't have the play for adjustment, as this could be detrimental when winching.

 

[krs]

Each time that I've had need to move or remove an aftermarket bumper we have two chairs that work perfectly as support. If they were less than perfect for it I'd use them with blocks on the arms. Maybe let some air out of the tires with the bumper supported and the bumper stays while the truck retreats. The mounting holes in the truck frame are slotted for fitment whether the bumper is or isn't.

And seriously, I was able to put the jack from our Subaru outback on top the frame in the wheel well and make it push upward enough to get a headlight fixture in and out. The light doesn't go much more downward than you see.



Just trying to help.



Oh, do you have a cherrypicker? That can help a lot in supporting the bumper.

 

[dresslered]

Great suggestions KRS but they just won't work in this application. When I originally installed the bumper, I slid it along two benches and a floor jack until it was on the supporting brackets. Right now, I am moving it around with a floor jack under the front hitch. The only problem is to get it to this stage you have to remove every bolt on the bumper and loosen every bolt on the mounting brackets. This is one sturdy beast!



I've got the OEM light assemblies out now so I am in process of building my custom harness for the quads. I hate to think of doing this all again if I pick up a rock on the road and break one of these lights.

 

[krs]

"I hate to think of doing this all again if I pick up a rock on the road and break one of these lights



Yeah, but it'll be easier the next time.



I know the buckstop. In fact one of my rears is by them and I picked it up at the "factory". ( ), met Darin there and considered a front at the same time.

 

[dresslered]

Yeah, but it'll be easier the next time.

KRS, I sure don't plan on getting good at this! Darin is a good guy and very helpful. I would have enjoyed seeing his shop but it is just a bit of a drive for me. Besides, why should I have him scrape knuckles when I can.

 

[krs]

"I would have enjoyed seeing his shop"



LOL! Maybe. I can give you a good idea what it was like by sending you to my house at 825 Trinkling Creek in Felton, actually Lompico. Very similar ambience.

 

[dresslered]

Son of a gun! We're neighbors?



Do I know you in person rather than by KRS? Do you belong to the San Jose Ramrunner's? If not, you should.



Enjoy the rain, David

 

[krs]

Gotcha!!



I saw a picture of you in the HVAC threads and do think we might have at least seen each other in passing 'cause you look familiar. I lived there for 20 years and still own the house as a rental but moved away from there when I retired (@47 yrs). some seven years ago so unless you've been there a while I'm probably wrong about recognizing you. .



Are you up in that canyon? The radio has been predicting big rainstorms in the Santa Cruz mountains tonight and Lompico always gets the worst of it.



I'm in Washington state now, and, ummm, it's raining here too.

 

[dresslered]

We've lived in Felton for about 7-1/2 years now (before that Sunnyvale). Perhaps we bumped heads at George's Log Cabin over a beer? I'm two blocks off of highway 9 overlooking the Henry Cowell entrance. I am on a sturdy sandstone hillside which allows the water to flow right off without the fear of slides. The rest of the town is quite soggy, however.

 

[krs]

Hi,

Yeah, I was pretty well known in George's and in the Woodshed but 7 1/2 years cuts it pretty close. I think I formally moved in early 1996. I probably still know some of your neighbors though. 20 years in that town and everyone knows you, or knows your dog.



Say hi for me to a clerk in the PO named Toni if you want to watch a woman cuss. LOL!

 

[dresslered]

Well, I hope that you're not too upset to learn that George's Log Cabin is now a yuppy "Monty's Place" (Pat died of Cancer) and that the Wood Shed is now a Teen Center. Just a long shot, but the "Birdog" is my next door neighbor.

 

[krs]

Well, well. He did the roof on my house. Kinda' surprised that he's still kicking, considering. Is he still doing piecemeal work, do you know? (as it happens I'm hassling with my property manager about getting the gutters fixed on my house there)



Edited in: what am I thinking about - he did that roof probably 15 years ago. He must have got a job by now, eh?



Anyway tell him Hi for Ken, and he'll know who you're talking about when you tell him that my dog's name was "Henry".



The yuppy sort of influx was one reason that I wasn't sorry to leave. The handwriting was on the wall, and I'd seen too much growth already.



Did you get the lights in, by the way?