Started my rhino grille swap on the Grand Wagoneer

[olllllo]

I had a few free hours last night and my unmounted rhino grille lured me out to the garage. Getting the stock grille off was as easy of a process as I could have hoped for. After getting it off I put a bolt loosely through the top mount to see how everything lined up,

First off... How about that fancy black spray paint that Jeep used to keep the stock paint from showing through the stock grille. Pretty huh? Anyone know a safe way to get rid of that layer of paint?
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5332_800.JPG

With the rhino grille up against my front clip, I got my first indication that this wasn't going to be a plug-n-play type swap...
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5336_800.JPG

As you can see, the tranny cooler is totally obstructing the ability to even get close to the tabs to see if I can line it up. There is another mounting tab from the stock grille at the bottom/center (visible in the next pic) that will have to be cut off as well, but I knew that if I had any chance of mounting the rhino, I would need to relocate the tranny cooler.

Given the way that the front clip is angled in relationship to the AC condensor, there is much more room at the top than the bottom. With that fact in mind I decided I would change the mounts to attach to the inside of the front clip instead of the outside, and likewise, have the tranny cooler mount on the inside of the brackets rather than the forward side as you can see in the picture above.

I think that the final result of the tranny cooler move came out pretty well...
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5337_800.JPG

... and there is enough room at the bottom between it and the AC condensor that I can put my fingers between them.
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5341_800.JPG

By this time, O'Reilly/Autozone were already closed so I couldn't go get new tranny cooler hose. It was also late enough that I felt that I probably shouldn't be cutting off the lower stock grille mount as most of my neighbors were well past "lights out". So I decided to leave that as it was and take a look at the headlights.

I have been told that you can use stock CJ headlights on a rhino swap, and given the fact that I actually had a stock CJ grille in my garage, I decided to pull out the stock GW lights and see how the CJ lights fit up there.

Once again, I found that this won't be exactly a direct swap...
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5344_800.JPG

As you can see in the pic, not only to the mounting tabs not line up (which I completely expected), they don't actually make contact with the sheet metal (not expected).

I think I am going to get some 1/2 wide strips of steel from Lowes on the way home and see if I can use them to connect from the light bucket to the sheet metal. If anyone has any better ideas, I am all ears, as I am *far* from a fabricator as this post ought to clearly show. :)

If the weather clears up a bit, I will be out there tonight and will hopefully be finishing the job up. Hopefully I will have some "success!" pics later.

[fulsizjeep]

please resize these pix down to at least 800 pix wide for us poor slobs on dial up...

[krek]

Nice job relocating the tranny cooler!

When I did my rhino coversion I wasn't comfortable "welding tabs" to hold the CJ headlights so I made sheet metal tabs that attached with 5/16 self tapping screws... once the trim ring is on it hides all of it.

[olllllo]

The pics are resized... sorry folks. For some reason I had it in my head that the limit was 1024.

Nice job relocating the tranny cooler!

When I did my rhino coversion I wasn't comfortable "welding tabs" to hold the CJ headlights so I made sheet metal tabs that attached with 5/16 self tapping screws... once the trim ring is on it hides all of it.

Thanks krek - I am glad to hear that is the approach you took w/ the headlights, as that is exactly what I am thinking about doing using those little strips of sheet metal they sell at Lowes and cutting them off with my dremel. What did you do about the plug? Did you find some CJ plugs or did you just do some DIY electrical connectors?

[krek]

I don't remember what I did about the electrical connections. It was a mud truck so I guess it's possible I didn't hook them up at all.

[sungoesdown]

my buckets look a little different. I was able to use self tapping screws to hold the buckets to the front. The trim ring covers them up
http://i166.photobucket.com/albums/u88/momentumauto/cjheadlight.jpg

[olllllo]

my buckets look a little different. I was able to use self tapping screws to hold the buckets to the front. The trim ring covers them up

I like those better. Do you remember the source?

[fulsizjeep]

thanks :cool:
The bigger buckets were used 63-72 or 73 and are a better fit for the round beauty rings if I remember correctly.

[sungoesdown]

I bought them used with the rhino grill on here. Not sure what they came off of. As far as the wiring, I used the existing harness with ends that came with the lights. I was able to rewire everything without splicing anything.

[men in black]

My buckets are the same as sungoesdown.
I used cable clamps to hold the bucket for alignment,
then welded the bucket in place. Then removed the clamps

I cut the back 2" of the bucket off. For clearance for the wiring harness.

http://i112.photobucket.com/albums/n192/pixelhound/DSC02764sm.jpg

[olllllo]

Well, I had a another couple hours to throw at the project Monday night in between a few downpours of rain.

For starters, I ran tranny cooler lines to the cooler and closed off that part of the project. I am really happy with the way that fits in its new location.
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5348_800.JPG

I also cut off the bottom middle mounting bracket for the stock grille, leaving the tab you see in the picture above. With those piece out of the way it was time to see if the grille actually fit...

http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5356_800.JPG

It fit like a glove... The hood comes down almost flush without any contact. Excellent!

Here is a view of the tranny cooler through the grille:
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5372_800.JPG

Next it was time to address the headlights and make some mounting brackets for them. I picked up some 1/2" wide steel strips from Lowes, and cut bracket pieces using my Dremel and mounted them in the stock screw holes as you can see in this picture:
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5357_800.JPG
In my first post I made a reference to the fact that the headlight plugs didn't match up. I would like to strike that comment from the record! I was using a modified headlight that had a couple of the connector pins turned and resoldered. When I put a new headlight up to the mounted bucket it plugged in and worked as if it were stock.
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5368_800.JPG

I ran out of time last night and had to call it a night, but all I really have left to do is build the brackets for the passenger headlight and mount it up. I also picked up some sandpaper and started trying to remove that sprayed on black paint with at least some success.

I will update this thread as I make further progress.

[Brizio]

Looks very nice!!!

[Bosqueboy]

I just did a Rhino conversion on my 87, mine is the same color as yours. If you need paint for the front valance try Dupli-color #8801542 (Creme). Bought it at Auto Zone $4.99 5oz can. It was almost a perfect match on my rig. One can did mine....

[olllllo]

I just did a Rhino conversion on my 87, mine is the same color as yours. If you need paint for the front valance try Dupli-color #8801542 (Creme). Bought it at Auto Zone $4.99 5oz can. It was almost a perfect match on my rig. One can did mine....

Thanks for the info. However, it will be getting a completely new color in the next couple of months. :thumbsup:

Here are a couple of pics after completing the passenger headlight. Now I just need to find a cheap/free set of those goofy pie pan covers to fill the holes, but overall I am really pleased with the way it came out.
http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5375_800.JPG

http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5376_800.JPG

[Brizio]

Looks great!!! Nice job!!!

[jtrain]

Nice job indeed! Thanks for posting the information. I'm looking at doing a Razor swap soon and the headlight information you shared will be helpful.

[81j10honcho]

http://dl.getdropbox.com/u/101948/wagoneer/rhino/resized/IMG_5376_800.JPGi see ur jeep is leaving its mark

[AKAMC]

Great info! I have a Rhino grille but wasn't sure if the headlight buckets from my 70 waggy would work. Looks like they do.:thumbsup:

[gedub]

Hey, I am new to this forum stuff and the Jeep world in general. I just stole a '87 Wagoneer off of eBay for $2600. After reading/viewing your efforts with the Rhino conversion, I am definitely going that direction. My question though is about the "goofy pie pan covers"? What exactly are those? I figured you could just buy an additional set of headlights and really blind the on-coming traffic! But hey, I'm new to this. Seriously though, your rig looks sweet!

[Slinger646]

Hey, I am new to this forum stuff and the Jeep world in general. I just stole a '87 Wagoneer off of eBay for $2600. After reading/viewing your efforts with the Rhino conversion, I am definitely going that direction. My question though is about the "goofy pie pan covers"? What exactly are those? I figured you could just buy an additional set of headlights and really blind the on-coming traffic! But hey, I'm new to this. Seriously though, your rig looks sweet!

Here is a J truck with the pie pans:thumbsup:

http://blog.hemmings.com/wp-content/uploads/2007/10/Hershey2007_5420_resized.jpg

[brubakes]

my buckets look a little different. I was able to use self tapping screws to hold the buckets to the front. The trim ring covers them up
http://i166.photobucket.com/albums/u88/momentumauto/cjheadlight.jpg

Did you need to trim the sheet metal around the bucket at all to make it fit? Also did you cut a hole in the bucket to squeeze wiring connector through.

[brubakes]

After going over this thread and this (http://www.ifsja.org/forums/vb/showthread.php?p=1006923#post1006923)thread I have to ask if there are different types of buckets that held the round headlamps. I can't tell by looking at other posted pictures if the buckets are different or if some people are not using the outer bucket. I was planning on using both as show in the picture, but it looks like I will have to trim a little to fit it inside the opening on the sheet metal.

http://i810.photobucket.com/albums/zz30/brubakes/J20/rhinobucket.jpg

[freeincolorado]

Nice job, I do like rhinos. BTW don't sell your fab skills short.

Nice job indeed! Thanks for posting the information. I'm looking at doing a Razor swap soon and the headlight information you shared will be helpful.

I just put a razor on my 89, went the easy (sort of) route and pulled a core support along with a grill. Looking at my stock core support it would have been kind of a PITA to adapt a razor to it. Good luck, you'll like the results.
:thumbsup:

[Anax]

I would like to putt the Rhino Grille onto my Jeep, However I can't seem to find one for sell. Do any of you guys have a link to a site or somewhere where I can buy one.

[orangebike]

I would like to putt the Rhino Grille onto my Jeep, However I can't seem to find one for sell. Do any of you guys have a link to a site or somewhere where I can buy one.


they come up for sale here quite a bit.....just have to have good timing and cash ready

[will e]

i think I have a nasty looking pair of the pie pans. If I remember correctly they would require some serious cleanup. PM me if you want them and since you posted up your project i will send them for free.


Sounds like you are going to get it painted soon. When you do, have them plug up all of the holes from removing the old grill and relocate your horns and have them clean those up too. Makes for a clean install.

[Jeeperman_82]

I, as so many of you, will be starting my own Rhino Grille convertion, if I can find a decent Grille. Instead of putting those, what I suspect, useless pie pans on, I plan on finding some amber-colored round semi-truck blinkers, that way, when I put an off-road bumper in place of the factory one, I'll still have visible blinkers and stay legal!

I am new to the site and will soon post pics and such. I own an '88 Grand Wagoneer, that I found on craigslist for $500. It is all stock and will soon start it's transformation in to either, "Hillbilly Wetdream" or, "Willy's Revenge."
:fsj:

[Karvin]

Bookmarking this page, I got a line up on a Rhino for $150. Expect to see my Razor up for sale in the very near future.