Ford Front End Kit: Sinister Diesel’s Super Duty

Sinister Diesel’s 2007 Super Duty Front End Kit Gives A Facelift To Aging Fords

Ford used basically the same cab from 1999 all the way to the 2016 model Super Duty. This makes it fairly easy to swap a newer front end onto older models. With a new truck costing $50K and up, it just makes so much more sense to take an older truck and make it new again. A front end conversion is one of the easiest and cheapest things you can do to an early Super Duty to freshen up its looks.

Now, we’ve known this was possible for some time, but the problem comes when you’re going to order a kit. What parts do you need exactly? MKM Customs has solved this problem. MKM Customs makes this swap a piece of cake by offering all of the many parts needed to get the job done in one kit. We got ours from Sinister Diesel. We also picked up a set of LED replacement headlight bulbs from Off-Road LED Bars to give the rig a much needed upgrade in the lighting department. With new parts in hand we headed to Pick-Up Parts in Mission Viejo, California, for the install. DW

Sources:
Sinister Diesel/MKM Customs
888-966-6543
www.SinisterDiesel.com

Offroad LED Bars
920-366-8662
www.OffroadLEDBars.com

Pick-Up Parts of Mission Viejo

FREQUENTLY ASKED QUESTIONS

How can headlights be installed on a 99-04 vehicle using the kit?

How to Install Headlights on a 99-04 Vehicle Using the Kit

If you’re looking to install new headlights on a 99-04 vehicle, you have a couple of straightforward options:

1. Hard Wiring with New Plugs (Pig Tails):
   • This method involves splicing the new headlight plugs directly into your vehicle’s wiring system.
   • It requires some technical know-how and the appropriate tools, but it allows a more customized installation.
2. Using a Headlight Adapter Harness:
   • For an easier installation process, opt for a headlight adapter harness.
   • This accessory allows you to connect the new headlights without altering the existing wiring.
   • Simply plug in the harness, and you’re good to go. This option is usually available as an additional purchase.

For vehicles from 2005 to 2007, the new lights are designed to connect directly without any modifications.

Are body shims included in the conversion kit, and are they necessary?

When purchasing our conversion kit, you might wonder about the inclusion and necessity of body shims. Here’s a detailed explanation to help you understand what to expect:

Inclusion of Body Shims

• Included Items: Our hardware kits come equipped with washers. These washers can be stacked and utilized as makeshift shims if needed during the installation process.
• Optional Add-ons: While our kits are designed to be installed without additional shims, we do provide the option to purchase specific body shims independently if you prefer or feel it’s necessary for your setup.

Necessity of Body Shims

• Design Intention: Our kits are engineered to function without the need for extra shims. This makes the installation straightforward for most standard uses.
• Varied Compatibility: Given the diverse nature of trucks—ranging from new, used, OEM, to aftermarket, and custom parts—the requirement for shims can vary. The history and composition of your vehicle’s parts could affect fitment, making shims a potential time-saver.
• Material Considerations: For trucks with components made from materials like steel or fiberglass, the use of shims might help achieve perfect alignment and an optimal fit.

In summary, body shims are not a standard inclusion in the kit, but they are available for purchase. Depending on your specific needs and the unique setup of your truck, they may become a beneficial addition to ensure a refined installation.

Is the conversion kit compatible with OEM and aftermarket body panels?

Compatibility with OEM and Aftermarket Body Panels

Wondering if the conversion kit works with both OEM and aftermarket body panels? It absolutely does! You can confidently use either option as they are both fully compatible with our conversion kits.

Key Points to Consider:

• Flexibility: Whether you choose OEM or aftermarket body panels, our conversion kit ensures a perfect fit.
• Cost Efficiency: Opting for aftermarket panels can save money, while OEM panels maintain brand consistency.
• Exclusions: Please note that body panels themselves are not included in the conversion kit.

This compatibility ensures you have various options to customize your vehicle according to your budget and preferences.

What are the options for mounting the bumper securely?

When it comes to securely mounting a bumper, you have several options to choose from, each providing different levels of sturdiness:

1. Basic Mounting: Without additional support plates, a bumper typically attaches with just one bolt on each side. However, this method requires the installer to create extra reinforcements to properly secure the bumper to the truck.
2. Enhanced Support with Mounting Plates: For a more secure installation, consider using mounting plates. These plates allow you to attach the bumper with two bolts on each side by lowering the mounting area. This is a common choice for increasing the durability of the bumper attachment.
3. Complete Bumper Kit: For the most robust option, opt for a full bumper kit. This package generally includes bumper plates, side supports (outriggers) that connect the frame to the outer side of the bumper in front of the wheels, and weld-in frame rail inserts. This setup is especially recommended when using an OEM-style bumper, as it offers maximum strength and support.
4. Frame Rail Inserts: During installation, if the frame needs trimming to accommodate the grill, frame rail inserts can be incorporated. These inserts fit directly into the trimmed sections and reinforce the frame once they’re welded in, adding another layer of security.

Each of these options varies in complexity and strength, so choose the one that best suits your needs and vehicle specifications.

Does the conversion require any welding?

Our conversion kit is designed for easy installation right in your driveway. It requires absolutely no welding, making it a straightforward project for any DIY enthusiast.

However, if you’re looking for additional customization, there are optional frame inserts available. These inserts can be welded in for enhanced durability, but it’s entirely up to you if you choose to use them.

In summary, welding is not necessary, but optional for those seeking extra reinforcement.

Are body shims available, and what are their uses?

Yes, body shims are available and serve a specific purpose in vehicle installations. These shims are typically used to adjust and level components during installation, ensuring a precise fit and alignment.

Why You Might Need Shims:

1. Adjustability: While many vehicle kits come equipped with washers that can double as shims, dedicated body shims offer more precise adjustments, especially when fine-tuning is required.
2. Compatibility Uncertainty: Each vehicle has a unique history, and the parts involved can vary widely. Whether using new, used, OEM, aftermarket, steel, or fiberglass components, having body shims on hand can save considerable time and hassle.
3. Installation Flexibility: Although installation kits are often designed to require no additional shimming, the unpredictable nature of parts and vehicle conditions means shims can be a valuable resource.

• Example Scenario: Suppose a part doesn’t align perfectly due to wear or slight size discrepancies. In that case, shims can bridge the gap, ensuring a snug and secure fit.

By incorporating body shims, installers can easily manage inconsistencies and achieve desired results with different vehicle assemblies.

Are body panels included in the conversion kit?

When evaluating whether body panels are included in a conversion kit, it’s important to note that they typically are not part of the package. The conversion kit generally focuses on other crucial components that facilitate the transformation process but excludes the actual body panels themselves.

Here’s what you can usually expect in a conversion kit:

• Mounting Hardware: All necessary bolts, screws, and brackets.
• Instructions Manual: Detailed guidance on installation.
• Additional Accessories: Any supplementary features like lights or badges.

If you need body panels specifically, you’ll have to purchase them separately from third-party suppliers or manufacturers.

What are the different bumper mount options available during installation?

Bumper Mount Options for Installation

When it comes to securing a bumper to your vehicle, there are several mounting options to consider, each with its own advantages:

1. Basic Mounting Option:
   The simplest method involves mounting the bumper with just one bolt on each side. However, this requires the installer to reinforce the area, as the support may be insufficient without additional modifications to strengthen the attachment points.
2. Improved Bolt Method:
   By utilizing custom plates, you can lower the mounting area on the trimmed frame rails. This allows for the bumper to be attached with two bolts on each side, which is a more common and secure option compared to the single-bolt method.
3. Full Bumper Kit:
   This comprehensive kit includes several components for maximum stability. It consists of bumper plates, side supports (outriggers) that connect the frame to the outside of the bumper in front of the wheels, and weld-in frame rail inserts. This setup is particularly recommended for those using an OEM style bumper, as it offers the most robust support.
4. Frame Rail Inserts:
   When installing the front end, it’s often necessary to trim the frame for the grill to fit properly. Frame rail inserts can be welded into these cut areas to reinforce and box in the trimmed section of the frame, ensuring added strength.

Each option offers different levels of security and complexity, so choose the one that best fits your needs and technical skill level.

Does the conversion kit include shims, and are they optional?

Are Shims Included in the Conversion Kit, and Are They Optional?

Yes, the conversion kit does include shims, and using them is entirely optional. While each kit is provided with washers that you can stack and use as shims if necessary, you also have the option of purchasing body shop-style shims separately. Although these kits are engineered to fit without additional shims, the diverse history of each truck and the varying types of parts utilized—be it new, used, OEM, aftermarket, custom, or materials like steel and fiberglass—mean that shims might be useful in certain situations. These shims could save you time by ensuring a precise fit tailored to your specific needs.

What is included in the package with the conversion kit?

1. MKM Customs’ 2007 Full Front End Conversion Kit arrived in one big box. Inside was everything we needed to get the job done. Here’s what’s included in the package:
   • Brackets: Essential for installing fenders, hood, lights, and grill.
   • Hardware Pack: All necessary fasteners to ensure a secure fit.
   • Templates for Trimming: Guides to help achieve a precise and clean installation.
   • Step-by-Step Instructions: Comprehensive guidance to walk you through every step.
   • Reversibility Feature: The kit is 100% reversible, allowing easy reinstallation of the original nose if you choose to sell the truck.
2. After disconnecting the lower splash shield and block heater plug, the four 18mm bolts securing the bumper to the frame were pulled and the bumper could then be removed.
3. The grille is secured to the header panel using four screws on top and a pair of clips on the bottom. With the bumper out, it’s much easier to remove these clips using a flat-head screwdriver or other small pry bar.
4. With the grille and bumper out of the way, the turn signals need to be removed to access the bolts that secure the header panel (the part that the grille, headlights, and turn signals mount to) to the radiator core support. The small 194-style bulb and plug need to be disconnected from the harness; a bulb and new plug comes with the MKM Customs kit. The larger 3157 bulb and plug will be reused in the new 2005-2007 style headlights.
5. Removal of the header panel can be done without removing the headlights, just be sure to disconnect the electrical connections on the headlights themselves. A combo wrench or the like has to be used on two bolts but the others can be removed with an air ratchet.
6. After all 10 8mm bolts were removed, the header panel simply lifts off the front end.
7. At this point, all parts that need to be pulled are off and the new MKM Customs parts from Sinister Diesel can be installed.
8. The MKM Customs header panel simply bolts into place using the same hardware that secured the factory-installed piece. The only exception to that is two new mounting brackets on either side of the radiator stack. MKM Customs supplies new ones. These are also bolt-on pieces.
9. The new bumper comes unassembled as some may prefer to paint the top cap rather than leave it in its raw, black finish. All the brackets needed come with the kit as well.
10. However, most of the stock hardware will need to be reused. MKM Customs supplies any extra hardware needed that you won’t find on your factory bumper.
11. After breaking down the stock bumper and swapping out the hardware, we had the core of the new bumper done in 10 minutes.
12. The top cap installs using a series of one-way clips (a light tap from a deadblow hammer or rubber mallet helps to seat them) as well as with a few ¼-inch bolts at either end of the bumper.
13. All put together, the new bumper was hung from the frame using the same mounting points as well as hardware the factory piece was secured with. We left it loose for now so it could be aligned with the headlights and grille to be installed next.
14. The new 2005-2007 grille installs just like the factory piece did using steel clips on the bottom and four Phillips screws up top. We find it easier to align the base without actually engaging the clips, and then lightly attach the top with the supplied screws. Once it’s hanging there by the top screws, the base can then be pushed back towards the radiator to lock the clips in place and then the top screws can be tightened down.
15. Next up are the new headlights, which bolt right in. The old turn signals and running light bulbs are 3157 and 194 models with the smaller of the two being the 194. The 3157 bulbs plug right in. The old bulb and plug fit in the new housing. The old 194 plug, however, will not work. We simply unplugged the harness there and plugged it into the new one on the new headlight housing.
16. Early model Super Dutys use a 9007 bulb, 2005-2007 trucks use an H13-style bulb, so the electrical connection is different. The MKM Customs 2005-2007 Conversion Kit came with bare pigtails, which entails cutting off the old plug and splicing in the new. It’s an extremely simple job that would only take a few minutes, but we just happened to have a 9007-H13 adaptor left over from a prior install, so we opted to use it instead.
17. One of the main reasons we did this whole conversion was to be able to upgrade our headlight bulbs to something more modern like this LED unit from Off-Road LED Bars. While this LED bulb would work in the older headlight, the newer version directs the light better to avoid blinding other drivers. It’s an easy plug-and-play job. No diodes, relays, or special wire harness were involved. Old bulb out, new LED bulb in.

How can headlights be installed on vehicles from 1999-2004 using the conversion kit?

16 Next up are the new headlights, which bolt right in. The old turn signals and running light bulbs are 3157 and 194 models with the smaller of the two being the 194. The 3157 bulbs plug right in. The old bulb and plug fit in the new housing. The old 194 plug, however, will not work. We simply unplugged the harness there and plugged it into the new one on the new headlight housing.

For vehicles from 1999-2004, you have two installation options:

• Hard Wiring: You can hard wire new headlight plugs using pig tails. This involves cutting off the old plug and splicing in the new one. It’s a straightforward task that should only take a few minutes.
• Headlight Adapter Harness: Alternatively, use a Headlight Adapter Harness for a plug-and-play solution. This harness allows you to install the new headlights without any wiring modifications. These adapters are available as add-ons for a hassle-free installation.

17 Early model Super Dutys use a 9007 bulb, while 2005-2007 trucks use an H13-style bulb, so the electrical connection is different. The MKM Customs 2005-2007 Conversion Kit came with bare pigtails, which entails cutting off the old plug and splicing in the new. It’s an extremely simple job that would only take a few minutes, but we just happened to have a 9007-H13 adaptor left over from a prior install, so we opted to use it instead.

What models of Ford vehicles are compatible with the front end conversion kit?

Ford used basically the same cab from 1999 all the way to the 2016 model Super Duty. This makes it fairly easy to swap a newer front end onto older models. If you’re considering a front end conversion, you’re in luck. Here’s a breakdown of the compatible models:

• 99-07 Ford Super Duty: These models are compatible with the conversion kit, allowing for a seamless update to a more modern look.
• 08-10 Ford Super Duty: Owners of these models can also take advantage of the conversion options available.
• 99-05 Ford Excursion: This model isn’t left out; it’s fully compatible with the front end swap.

When it comes to selecting your new look, you have a couple of stylish options:

1. 08-10 Ford Super Duty Nose: Perfect for those who want a subtle, newer aesthetic while maintaining the classic Super Duty feel.
2. 11-16 Ford Super Duty Nose: For a more contemporary upgrade, this option brings the latest design elements to your older model.

By understanding the compatibility and style options, you can easily transform your vehicle’s appearance, blending the classic durability of older models with the sleek design of newer ones.

Is the conversion kit bolt-on, and can it be installed without welding?

The MKM Customs header panel simply bolts into place using the same hardware that secured the factory-installed piece. The only exception to that is two new mounting brackets on either side of the radiator stack. MKM Customs supplies new ones. These are also bolt-on pieces.

For those eager to upgrade without hassle, our conversion kit is designed with you in mind. It is 100% bolt-on, ensuring a straightforward installation process that even a weekend warrior can tackle in their driveway.

Installation Highlights:

• No Welding Required: The kit fits seamlessly without the need for welding. This means fewer tools and less time spent on the job.
• Optional Customization: Should you desire added stability or customization, optional add-on frame inserts are available. These parts require welding but only if you choose to enhance your setup further.

This blend of simplicity and potential for customization makes it an ideal choice for both novice and experienced enthusiasts looking to transform their vehicle with minimal fuss.

Are there headlight adapters available for vehicles from specific years?

“Early model Super Dutys use a 9007 bulb, 2005-2007 trucks use an H13-style bulb, so the electrical connection is different. The MKM Customs 2005-2007 Conversion Kit came with bare pigtails, which entails cutting off the old plug and splicing in the new. It’s an extremely simple job that would only take a few minutes, but we just happened to have a 9007-H13 adaptor left over from a prior install, so we opted to use it instead.”

For vehicles from 1999 to 2004, you have two primary options for installing new headlights:

1. Hard Wiring: This involves cutting off the old headlight plug and using new pigtails to connect the new headlights. It’s a straightforward process that requires some basic wiring skills.
2. Headlight Adapter Harness: This option eliminates the need for any wiring. Simply plug in the new headlights using an adapter harness, making the installation process quick and hassle-free. These harnesses are available for purchase as convenient add-ons.

For 2005-2007 models, the transition is even smoother. These trucks can easily plug into new lights with no modifications required, thanks to the compatible H13-style bulb connection. This ensures a seamless upgrade without the need for additional adapters.

What are the bumper mounting options provided in the conversion kit?

All put together, the new bumper was hung from the frame using the same mounting points as well as hardware the factory piece was secured with. We left it loose for now so it could be aligned with the headlights and grille to be installed next.

When it comes to mounting the bumper, several options are available to ensure a secure fit:

1. Basic Installation: Using the existing hardware, the bumper can be mounted with a single bolt on each side. While straightforward, this method might require additional reinforcement for enhanced stability.
2. Enhanced Mounting Plates: By incorporating specialized plates, you can lower the mounting area, allowing the bumper to be securely attached with two bolts on each side. This is a common choice for those seeking a balance between ease and security.
3. Comprehensive Bumper Kit: For maximum strength, consider the full kit, which includes additional bumper plates, side supports, and weld-in frame rail inserts. This setup is ideal for those using an OEM-style bumper and looking for the most robust installation.
4. Weld-In Frame Inserts: During the bumper installation, if any frame trimming is necessary to fit the grille, welding inserts into these areas can provide extra support and maintain the structural integrity of the frame.

By considering these mounting options, you can ensure that the new bumper is not only securely installed but also perfectly aligned with the vehicle’s aesthetic and functional requirements.