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I finally got rid of all the bumps that were around the headlights that made My car look like it had measels and I must say it was a lot easier than I thought it was going to be. After I removed the old Headlight/Header Support bar I could see what was causing the lumps. All of my aluminum rivets had corroded and pushed the fiberglass up. I am really not sure (other than shear luck) what was holding the headlight bar in place. If anyone else has these bumps they should look very closely and see how corroded their rivets are and how well their headlight bar is still held in place. After the old one was out, I cleaned up all of the old adhesive and bonded a new style bar (73 and up) in place with some panel bond adhesive. I cut some strips out of oak and placed those over the bumps and then clamped the new bar in place. This sucked all the bumps down and when I took the boards off they were all gone!!! I tried to get some pictures with the clamps off, but nothing turned out well due to all the chips and scratches. I still have some work to do, but this sure did solve a lot of problems for me hopefully this information will help someone else.
It's weird, if you look at the rivets on the old headlight bar they have completely rusted away, but if you look at the metal headlight bar itself, it is not that rusty. You would think looking at the metal bar the rivets would still be good. Not the case at all.
This is a shot of it flipped upsided down. I think it helps having the front clip off, but I could see this being done easily on the car as well.
Here is a shot of the topside. The oak strips really helped pull the bumps down. Not long to make either. Good opportunity to play with the table saw...
....it was a lot easier than I thought it was going to be...If anyone else has these bumps...
Nice work. The repair you made is a heckuva lot easier to do with the doghouse off the car. It's a major PITA with everything in place. Your "measles" is a common condition. Over time, the aluminum rivets react with the steel header bar and create the condition.
Is the header bar actually riveted through the fiberglass? My header bar is separating from the front clip and I have been wondering for a while how to fix it or if it was fixable. If the bar is bonded and riveted in place then I assume there are rivet heads to deal with on the top side when complete? I'd appreciate any additional info. Thanks.
Is the header bar actually riveted through the fiberglass? My header bar is separating from the front clip and I have been wondering for a while how to fix it or if it was fixable. If the bar is bonded and riveted in place then I assume there are rivet heads to deal with on the top side when complete? I'd appreciate any additional info. Thanks.
The steel headlight bar is riveted to the V shaped piece of fiberglass as seen in the first picture. That piece of fiberglass is then glued to the underside of the of the front end. If you remove both pieces and then replace them with the newer style steel header bar you will have gotten rid of all of the rivets and will never have to worry about them again. There are no rivets going to the upper fiberglass headlight surround. Very nice repair process GM has devised for us. Thanks everyone else for the compliments....