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DURTYEF3 · 4th May 2008, 09:04 PM

UPDATE:

Continuing where i left off, i removed all the PFL parts including the bonnet and decided now to start removing all the niggly little things like Radiator, Air-Con Radiator and anything that will obstruct the welding that needs to be done on the Radiator support & also to make it easier for whoevers going to weld it. Whilst i was at it i searched up NZH and come across Badcf4's Dominator thread and learned brofessionally how to remove my aircon etc. Cheers mate.

Bare Front

Now theres two ways i've found around to make this conversion possible. One being to remove completely the PFL radiator support by Spot welding the odd 20+ spot welds down each side, or buy cutting the top half of the FL radiator support and the same to the PFL one and weld FL top half on PFL bottom half of the radiator support. Confusing?.. heres some pics (via honda-tech)

Option #1

Use whole radiator support. Supposedly a bit more time consuming having to drill out every spot weld and then re-welding,lining up etc.

BOLTING YOUR SUPPORT ON IS NOT AN OPTION

Option #2

Use the "T Bar" method which is supposedly quicker as your replacing the difference between the PFL & FL supports. Places like Password JDM supply the "TBAR" now.
User on H-T

Anyways after thinking a bit i decided with #2 mainly because it seems the way to go. Plus your not really drilling the bottom of the PFL support which is i guess a main structural point and has been welded with strong factory welds . Top half is mainly for headlight and radiator support and this will suffice.

After it was all bare and ready to be welded up. I pmd b16a2 aka luke who has done a few of these conversions now and done a bit of fabriation work for various nzh'ers and arranged for him to come and weld the support on etc seen as i suck @ welding + don't have access to one.

The only thing different between the two supports is the top half. headlight mounting etc.

First things first, you need to cut the PFL radiator support above half of the headlight housing like in pic and the whole of the middle support beam off..see pic.In my case luke decided to cut further down im guessing to make it a bit stronger with a bit more to weld as opposed to the H-T user.

PFL Radiator Support Cut

PFL Radiator Support goneburger

Once removed you'll want to clean around where you've just cut to make sure when you weld the FL support on you get nice contact.

Luke (b16a2) getting his grind on

Take the PFL support and match it with the FL support marking with a felt or the likes so you know where to cut. Take your time!!

Cutting FL support to match. Watch ya fingers

Again clean your work...

Moarrr Grinding/Cleaning

Heres where you need a welder or at least someone that knows what they're doing, hence me behind the camera,

Before you weld the PFL support on i suggest you get a grinder and grind off a bit of the PFL headlight surround(if thats what you call it)? that stops the FL headlights from being positioned right. pics.

Cut this off so headlights can fit in headlight housings

Luke welding Top half of FL Radiator support

More welding

Front support on, grinded,cleaned & painted

Thats that bit done

, Thanks to Luke for taking time out from his studies to help a fellow NZH'er out. Appreciate it man. Top job.

So now the FL support is on the biggest part of the conversion is done, now all thats left is to test fit the parts,headlights,bumper etc and check it all is sweet, and then get to the wiring side of things which i will document as well.

Note: You may want to also use a FL bonnet latch assembly and cord as ive found the PFL cord is way too long (not really that much of a hiccup) and the PFL doesnt match up so good with the FL latch under the bonnet. In my case i also managed to grab the FL items when i did the front cut, so it was made much easier for me. Which ever way it shouldnt be hard to figure out.

pics (note: just test fit all just sitting there hasn't been aligned etc as i have more to do)

Headlights,Guards, Grille on

The old front end

Bit of a panda at the moment, but will be painted when i can get that sorted

The new front end

Well now i got the car looking like a car again, im pulling the parts back off to do the wiring (Note: you may have noticed i already attacked the loom prior to doing the conversion, so the wiring was done before.). The wiring is all done and ill update this post with pics and how i did it etc.

4th May 2008, 09:04 PM	#2 (permalink)
DURTYEF3 Senior Member 7,000rpm (Peak Power) Join Date: Jun 2006 Posts: 3,669 Location: Papatoetoe	UPDATE: Continuing where i left off, i removed all the PFL parts including the bonnet and decided now to start removing all the niggly little things like Radiator, Air-Con Radiator and anything that will obstruct the welding that needs to be done on the Radiator support & also to make it easier for whoevers going to weld it. Whilst i was at it i searched up NZH and come across Badcf4's Dominator thread and learned brofessionally how to remove my aircon etc. Cheers mate. Bare Front Now theres two ways i've found around to make this conversion possible. One being to remove completely the PFL radiator support by Spot welding the odd 20+ spot welds down each side, or buy cutting the top half of the FL radiator support and the same to the PFL one and weld FL top half on PFL bottom half of the radiator support. Confusing?.. heres some pics (via honda-tech) Option #1 Use whole radiator support. Supposedly a bit more time consuming having to drill out every spot weld and then re-welding,lining up etc. BOLTING YOUR SUPPORT ON IS NOT AN OPTION Option #2 Use the "T Bar" method which is supposedly quicker as your replacing the difference between the PFL & FL supports. Places like Password JDM supply the "TBAR" now. User on H-T Anyways after thinking a bit i decided with #2 mainly because it seems the way to go. Plus your not really drilling the bottom of the PFL support which is i guess a main structural point and has been welded with strong factory welds . Top half is mainly for headlight and radiator support and this will suffice. After it was all bare and ready to be welded up. I pmd b16a2 aka luke who has done a few of these conversions now and done a bit of fabriation work for various nzh'ers and arranged for him to come and weld the support on etc seen as i suck @ welding + don't have access to one. The only thing different between the two supports is the top half. headlight mounting etc. First things first, you need to cut the PFL radiator support above half of the headlight housing like in pic and the whole of the middle support beam off..see pic.In my case luke decided to cut further down im guessing to make it a bit stronger with a bit more to weld as opposed to the H-T user. PFL Radiator Support Cut PFL Radiator Support goneburger Once removed you'll want to clean around where you've just cut to make sure when you weld the FL support on you get nice contact. Luke (b16a2) getting his grind on Take the PFL support and match it with the FL support marking with a felt or the likes so you know where to cut. Take your time!! Cutting FL support to match. Watch ya fingers Again clean your work... Moarrr Grinding/Cleaning Heres where you need a welder or at least someone that knows what they're doing, hence me behind the camera, Before you weld the PFL support on i suggest you get a grinder and grind off a bit of the PFL headlight surround(if thats what you call it)? that stops the FL headlights from being positioned right. pics. Cut this off so headlights can fit in headlight housings Luke welding Top half of FL Radiator support More welding Front support on, grinded,cleaned & painted Thats that bit done , Thanks to Luke for taking time out from his studies to help a fellow NZH'er out. Appreciate it man. Top job. So now the FL support is on the biggest part of the conversion is done, now all thats left is to test fit the parts,headlights,bumper etc and check it all is sweet, and then get to the wiring side of things which i will document as well. Note: You may want to also use a FL bonnet latch assembly and cord as ive found the PFL cord is way too long (not really that much of a hiccup) and the PFL doesnt match up so good with the FL latch under the bonnet. In my case i also managed to grab the FL items when i did the front cut, so it was made much easier for me. Which ever way it shouldnt be hard to figure out. pics (note: just test fit all just sitting there hasn't been aligned etc as i have more to do) Headlights,Guards, Grille on The old front end Bit of a panda at the moment, but will be painted when i can get that sorted The new front end Well now i got the car looking like a car again, im pulling the parts back off to do the wiring (Note: you may have noticed i already attacked the loom prior to doing the conversion, so the wiring was done before.). The wiring is all done and ill update this post with pics and how i did it etc. Last edited by DURTYEF3; 7th May 2008 at 10:32 PM.