I removed the headlamp supports a while back and they were ruined from Galvanic corrosion. The headerbar which is mounted to the underside of the nose of the car is all rusted. I want to replace it, my question is:
What is the proper procedure for doing this? How do I determine how to align it, so when I attach new headlamp supports ( I still need to acquire) they will provide proper clearance with the rest of the headlamp assembly? Do they bolt into place? I did not see any bolts, but there was much rust. Are they glued? How do I remove them? If they are glued into place, what do I use for glue? Are new supports going to have all the necessary holes drilled and tapped to accept everything?
Know of a god source for headlamp supports?
1974 LS4 Coupe

Thanks

Todd

 

I did mine a couple years ago,, you will have to dig into the fiberglass to get at the rivet heads to drill them out,, then if your lucky it will just fall down,, but most likly its still glued a little. Its a difficult part to find,, (if I remember), I ended up rebuilding mine, there was enough good metal for me to replace the rot. I would imagine a replacement part would have the holes already drilled and if your lucky they are at the correct locations,,, but don't count on it,,) Maybe you can trace its location with a black marker to keep reference,, before removal.

I do beleive an installation kit or proper rivets are available, and gluing back in place is a must, I used structual adhesive (epoxy). And instead of rivets, I used 1/4in stainless countersink screws, glued them in the fiberglass, raised the headerbar and tightened nuts snug. works and looks good.

 

I did mine whilw I had the body off so there was a lot less hardware in the way. I bought a new header bar and the support brakets, mine was pretty crusty.
I'm pretty sure the 73 and up bar was just bonded in place and did not use the rivits and bonding strip.

here are a few photos of how I did mine.

old one was half hanging off and was crumbling To remove what was left I used my heat gun and a scraper to work the old Vettebond and bar off. Careful, if you get it too hot it will blister the paint.



Once the panel was removed I took 80 grit paper and cleaned up the surface to remove any rust or bonding adhesive and cleaned up with some acetone.


I then clamped the bar in place with the light buckets so I could mark the header bar and body alignment, once marked I remove the light assemblies.
I used a 2 part epoxy Structural panel adhesive to bond the header bar to the body, mine had a long setup time so it allowed me to mount the corner brackets and get everything clamped in place. Check your alignment marks one last time cause it isn't ever going to come off again without taking half the body panel with it!
You can clamp it along the hood opening and along the headlight openings.


I left it clamped for about 24hrs then bolted all the assemblies back in

 

When you get ready to start looking for the headlight pieces shoot me a pm.I have all this stuff new,and used depending on what you want to spend.
The last poster made the very most important statement....bolt everything in place w/the proper clearance,mark it,THEN disassemble,check alignment marks again,and bond.There is adjustment in the pieces,but make sure that you pre-fit everything.This really isn't a hard job,but not alot of fun manuvering the headlight assemblies in,and out.