How to Install Billet Grill in a 2000 Lightning
The upper grill install would be
the same for any 1999- 2000 F150
By Brooks Marine
Click on the thumbnails to see larger versions
First the Upper Grill
first - take these plugs out of the radiator cover
second - take bolt out of intercooler coolant tank and push back. then remove radiator cover.
third - take out screws along top of grill surround.
fourth - remove side marker lenses by taking this screw out.
fifth - take out the remaining screws
that hold the grill surround on.
sixth - push out these black plugs
that are in the bottom of the surround.
I found that it
was easier when i took out the headlight assemblies.
seventh - the instructions said to only break out the tabs on either side of the surround, but I didn't like the first one on top and bottom poking thru the grill, so i broke them off as well. to break off the tabs, lightly score them with a utility knife then apply pressure, and score again. they should break off cleanly. go back and trim as needed.
eighth - get grill ready to go in.
make sure none of the slats are bent. (ups man dropped
mine & bent them to hell.. easily repaired) test fit
the grill to see if it needs anything else done to it.
after measuring to see if it was
centered, I drilled holes in the grill and surround. I
used 3/16" X 1/4" rivets and rivet washers to
hold everything together
put it all back together in reverse..
now enjoy a frosty cold beverage of your choice and
stare at your new grill.
Now to Install the Lower Grill.....
okay.. first off, a parts list.
Dremel - if you don't have one, get one!!!
90
degree adapter for the Dremel, several bits -
to bore
holes in bumper cover, and to sand down billet insert.
(trust me, it wont fit) a good pair of gloves
this is the best bit to shave down the billet inserts.
Okay.. first off, jack up truck and place on jack
stands.
take these plastic plugs out of the rubber
piece on the bottom of the cover.
Now you'll be able to reach the screws holding the stock insert in.
Here's what it'll look like.
I lost a lot of time on the next few things.
I
had
to grind a LOT of metal off of the billet insert, then i
had to go to Lowe's & buy the 90 degree adapter and
more bits to grind down the insert. the one bit i have a
picture posted of is the best bit i found to cut thru
the metal.
test fit your grill & grind it down as needed.
try not to scratch your paint.
(note - yelling at the
insert to "FIT DAMMIT" will not work. it gets upset and
will strike you)
after grinding and test fitting, drill 3/16"
holes in
the tabs for the rivets.
(that is what size I used,
along with 3/16" rivet washers)
after drilling holes in the tabs, have someone hold grill in place while you take the Dremel with the 90 degree adapter, get under the truck and drill holes in bumper cover using the holes in the tabs to show you where to drill.
after that, rivet into place and you're
done.
reinstall the plastic clips in the rubber piece
under truck.