Broke the grill/headlight housing on my 89 CSX!

[Shadowjake]

When I was stripping down the engine bay to get it ready for paint yesterday, I forgot a bolt and friggin' broke the thing!:banghead:

http://lh3.ggpht.com/_rvhD6gH1e6I/S9T2lB5e9VI/AAAAAAAADJE/OhVcIs5FYw4/s800/P1000760.JPG

http://lh5.ggpht.com/_rvhD6gH1e6I/S9T2mG2UdeI/AAAAAAAADJI/b7if_V2delo/s800/P1000761.JPG

Is this the same as any shadow grill? What years are compatible? The CSX insert is fine, just this frame piece needs to be replaced. Thanks!

Jake

[supercrackerbox]

Ouch, that sucks!

I seem to remember something about Shelby using Sundance grilles instead of Shadow ones, but I don't know exactly what the difference is. Hopefully someone else knows more.

[rich tideswell]

you can fix that one with some sandble 2 part epoxy if you have all the broken chunks. after the repair and paint, youwont be able to tell it was ever broken

[Shadowjake]

How strong is the epoxy? Would it be more likely to break again in the same spot or is sandable epoxy pretty reliable and long lasting?

Do you have any recommendations on which brand to get?

[raccoon]

I seem to remember something about Shelby using Sundance grilles instead of Shadow ones

I would look into this

[rich tideswell]

How strong is the epoxy? Would it be more likely to break again in the same spot or is sandable epoxy pretty reliable and long lasting?

Do you have any recommendations on which brand to get?

A little Bondo will do if you have some handy. Permatex has platic/ fiberglass epoxyes in little syringe type dispensers that work well too, but I can't commonet on how sandable they are. J.B Weld is a good strong epoxy but it probably is not going to be that easy to sand

I also seem to recall you guys saying that the outer grill/ headlamp bucket assmebly is common with shadow/ sundace/ duster 89 and newer, but i can't find the thread as to where

[TonaKid62]

i have used a 2 part epoxy on my daytona ground effects before. it works really well, you just build it up and mold it and when your done its just as strong because if flexes a little with the plastic. i will see if i can find it and tell you the exact name.

[CoolV300C]

That's not CSX specific, so no worries.

Same as a sundance or duster. :thumb:

[Shadowjake]

Hey, thanks gentlemen! I will see if I can epoxy it or find one cheap in a junk yard. If epoxy doesn't work, will any 89+ sundance/duster one work? No shadow ones will? Thanks.

Jake

[supercrackerbox]

Is that the year that the Shadows got the crosshair grille? I'm thinking that would have been molded all as one piece, whereas the Sundances still got the mesh grille inserts, which could have been removed and therefore would make more sense for installing the CSX grille insert.

This is purely conjecture here, I'm just thinking out loud. I don't actually know . . .

[CoolV300C]

Is that the year that the Shadows got the crosshair grille? I'm thinking that would have been molded all as one piece, whereas the Sundances still got the mesh grille inserts, which could have been removed and therefore would make more sense for installing the CSX grille insert.

This is purely conjecture here, I'm just thinking out loud. I don't actually know . . .

You are exactly right. The Shadow had the cross hairs molded in. Any Sundance or Duster would do.

You need to go to the junk yard, they are a dime a dozen. Especially if you were getting it painted anyway. Paint one that is in perfect condition, not a repaired one you will be reminded of whenever you open the hood.

[rich tideswell]

Is that the year that the Shadows got the crosshair grille? I'm thinking that would have been molded all as one piece, whereas the Sundances still got the mesh grille inserts, which could have been removed and therefore would make more sense for installing the CSX grille insert.

This is purely conjecture here, I'm just thinking out loud. I don't actually know . . .

no i think you're right as well that the cross hairs are molded in, he needs 89+ sundance or duster.

[Turbodave]

89-90 Sundance/Duster will work 100%. Not sure if they changed at all in the mounting after 91 (the core support changed this year).

Shadow is all one piece and won't work like others have said.

[Shadowjake]

Well I ordered one. Asked for a 1989 or 1990 sundance header panel. They got a 1992 header panel in and told me that they are all the same from 1989-1992. I argued with him for a while showing him that they are different and wouldn't budge. I had already paid for it in order to order it. So I guess I'll have to make it work. Looks like I can cut a few vertical supports and sand them flush to make it work. What do you guys think?

Here's the original:

https://lh4.googleusercontent.com/_rvhD6gH1e6I/TapqScjw74I/AAAAAAAADnM/b0-67xYcAOk/s800/P1020014.JPG

Here's the replacement I got:

https://lh4.googleusercontent.com/_rvhD6gH1e6I/TapqO7cyXnI/AAAAAAAADnM/ekS64etNKNY/s800/P1020015.JPG

[Shadowjake]

Well I got it fixed today. And after closer inpection, it actually looks like Shelby had to modify the header panels he used too for them to support the grill insert. This is the original shelby header panel. You can see the cut marks on the left and right side for the grill insert tabs to go in.

https://lh3.googleusercontent.com/_rvhD6gH1e6I/Tat_C-54MYI/AAAAAAAADns/QWysMBAPJmM/s800/P1020022.JPG

https://lh6.googleusercontent.com/_rvhD6gH1e6I/Tat_Fz3fXCI/AAAAAAAADnw/-LwfVbYzN58/s800/P1020024.JPG

Using the original as a template, I began by marking out where I needed to remove material.

https://lh6.googleusercontent.com/_rvhD6gH1e6I/Tat-2hkwkTI/AAAAAAAADng/xe2yYdq-pLM/s800/P1020016.JPG

https://lh3.googleusercontent.com/_rvhD6gH1e6I/Tat-2COT8cI/AAAAAAAADnc/aGO7RnAsHOs/s800/P1020017.JPG

https://lh4.googleusercontent.com/_rvhD6gH1e6I/Tat-9acjK0I/AAAAAAAADnk/K8uV8UY0ylY/s800/P1020020.JPG

https://lh5.googleusercontent.com/_rvhD6gH1e6I/Tat---fic6I/AAAAAAAADno/qpzwPSP6fdc/s800/P1020018.JPG


http://www.youtube.com/watch?v=bRoaUJLoEOo

Then I started cutting. All I used were the tools in the picture to complete the job. Word of caution though . . . fine powder flies everywhere when you are cutting so wear a dust mask and safety glasses and plan on a long cleanup.

https://lh6.googleusercontent.com/_rvhD6gH1e6I/Tat_iAb-0JI/AAAAAAAADog/vmDKA-x0f9I/s800/P1020037.JPG

https://lh3.googleusercontent.com/_rvhD6gH1e6I/Tat_IBh3_QI/AAAAAAAADn0/AA6gBooHl9A/s800/P1020025.JPG

https://lh5.googleusercontent.com/_rvhD6gH1e6I/Tat_MZxUoqI/AAAAAAAADn4/tTOwzdnF-Tc/s800/P1020026.JPG

Here's a test fit of the grill insert. I opted to leave two vertical supports in place instead of only 1 like Shelby did since this is where it broke. Not only will it look more symetrical, but it should also be stronger. If I don't like the look later, I can always chop it out down the road.

https://lh4.googleusercontent.com/_rvhD6gH1e6I/Tat_OHWQ5HI/AAAAAAAADn8/xBo_pLUUlds/s800/P1020027.JPG

Here's how it looked in the original header panel.
https://lh6.googleusercontent.com/_rvhD6gH1e6I/Tat_VfP1_eI/AAAAAAAADoI/EJpzHiMTMAA/s800/P1020029.JPG

In order to get the grill insert to slide all the way in, Shelby had to make a notch in the center vertical support like this:

https://lh6.googleusercontent.com/_rvhD6gH1e6I/Tat_bgOQozI/AAAAAAAADoQ/Mvx15lOkLFw/s800/P1020030.JPG

Instead of removing so much material for no real reason (also where mine broke) and compromise strength, I removed only what was necessary for it to slide in.

https://lh5.googleusercontent.com/_rvhD6gH1e6I/Tat_YZbQKkI/AAAAAAAADoM/Or3XogESb_c/s800/P1020031.JPG

Here is how the whole thing looks mocked up on my front end. The 2 verticals blend in to the radiator support and I think it looks just fine.
https://lh4.googleusercontent.com/_rvhD6gH1e6I/Tat_b7pF5eI/AAAAAAAADoU/tj_UuJSbdUU/s800/P1020033.JPG

And with just the header panel without the insert:

https://lh4.googleusercontent.com/_rvhD6gH1e6I/Tat_dpq-QaI/AAAAAAAADoY/bWO127wxavE/s800/P1020035.JPG

Here is the waste that was removed.

https://lh3.googleusercontent.com/_rvhD6gH1e6I/Tat_hCe3ipI/AAAAAAAADoc/LQEkPTXrU2I/s800/P1020038.JPG

[CoolV300C]

Looks good, but it must be different for that year. I got one from a junkyard duster and put a csx grill insert in with no mods. Alls well that ends well. Looks good.

[Shadowjake]

Looks good, but it must be different for that year. I got one from a junkyard duster and put a csx grill insert in with no mods. Alls well that ends well. Looks good.

What year duster header panel did you get?

[CoolV300C]

Not sure. Just grabbed it at a jy thinking it looked like it would work. Did not check the year.

[Nemesismachine]

Could have just used plastifix and saved like 3 hours. Basically, why didn't you just glue it back together? :P

[Shadowjake]

Could have just used plastifix and saved like 3 hours. Basically, why didn't you just glue it back together? :P

I tried epoxying it back together but it looked like crap afterward. It wasn't just cracked, it was missing a chunk. It really wasn't that hard or time consuming and it looks much better than if I would have half --- glued it. Especially once it is painted.