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Shady tree fix on broken grille mounting tabs...87 900T
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Posted by JohnB (more from JohnB) on Fri, 4 Jul 2003 04:36:24 Share Post by Email
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OK, not the best/cleanest, but cheap and it doesn't show from the outside. With a shot of rustoleum it will outlast the rest of the Q@#%QW#$% cheap plastic grille.

These are simple right angle brackets that attach the grille to the radiator support (same member the grille normally attaches to). For the broken tabs on the grille, pop out the plastic rivet about an inch in from the broken tab that holds the chromed part of the grille to the black plastic. You''ll use the hole to pass a 6-32X1" screw (use a washer under the screw) through the grille into a bracket.

Get a few Stanley 2" right angle corner brackets or bend up some 1/8" X 1/4" strap metal and drill both holes. The Stanley corner brackets come pre drilled and countersunk so you can use one of the holes closest to the vertex of the corner to bolt the top of the bracket onto the car. Slice off the metal above this hole. Measure roughly how much you need to cut off to allow the bottom part of the bracket to slide into the grille (too long and the grille will stick out too far, too short and you won't have a bracket to drill/tap into!)

I used a 1/8" 4" cutoff wheel on my trusty cheap Harbor Freight grinder ($20, NS!)
Use the cutoff wheel to slice the brackets and knock the edges off the cut.

Here's the trick...use a (3/32, i.e. .094) or by the book a #36, i.e., .106) drill and a
6-32 tap on the bracket. The bracket is marked by drilling through the existing hole in the grille where you pulled the little plastic rivet out about an inch from the broken tap. Remove the grille and the brackets after you've marked the hole and finish the tapped hole in the brackets. Assemble the brackets to the grille and then the grille to the car. A little dab/spray of rustoleum and you're good to go.

With the 3/32 drill bit you'll have to force the tap a bit...back it out if it turns too hard to clear the shavings, but it worked for me on the soft metal of the bracket.

Not a bad 4th of July morning on theÊwhole.

EOM



posted by 68.50.1...
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