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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

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1 MKM Customs’ 2007 Full Front End Conversion Kit arrived in one big box. Inside was everything we needed to get the job done.
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
7 & 8 At this point, all parts that need to be pulled are off and the new MKM Customs parts from Sinister Diesel can be installed.
9 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.
10 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.
11 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.
12 After breaking down the stock bumper and swapping out the hardware, we had the core of the new bumper done in 10 minutes.
13 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.
14 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.
15 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.
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.
17 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.
18 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.
19.
19 & 20 Old headlight housing vs. new. The old ones did a somewhat primitive job of directing the light. Plus, they had faded to the point where they were barely shedding any light on the road at all. The new units from MKM Customs look better and they’ll do a much better job lighting up the road ahead.
21 Done, looking good and ready for another 14 years of service.

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

Is there an installation video available for the conversion kit?

Yes, there is an installation video available for the conversion kit. You can easily access it online to guide you step-by-step through the installation process.

This video aims to provide clear and concise instructions, ensuring a smooth setup. Whether you’re a seasoned mechanic or a DIY enthusiast, the visual aid can help simplify complex steps.

For your convenience, the video is typically found alongside the product listing or in the support section of the retailer’s website. Make sure to give it a watch before starting your project to familiarize yourself with the process and tools needed.

Finally, if you’re using a third-party video source like YouTube, search for the product model followed by “installation guide” to find relevant tutorials.

 

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.

 

How does the nutcert/rivnut tool work for installing brackets?

Installing brackets with a nutcert or rivnut tool is a straightforward process that transforms a regular hole into a reliable, threaded one. Here’s how it works:

  1. Drill the Hole: Begin by drilling a hole in the metal surface where you need the bracket installed. The diameter should match the size of the nutcert you plan to use.
  2. Insert the Nutcert: Place the nutcert into the drilled hole. Ensure it sits flush with the surface for optimal stability.
  3. Use the Tool to Secure: Attach the nutcert tool to the installed nutcert and engage it. This tool is designed to “crush” or compress the nutcert, causing it to expand and grip the surrounding material securely.
  4. Remove the Tool: Once the nutcert is firmly in place and properly expanded, remove the tool. You’re left with a strong, threaded hole.
  5. Attach the Brackets: With your new threaded hole, simply bolt the brackets on and off with ease. This setup allows for secure attachment and easy removal when needed.
Why Use the Tool?

Using a nutcert or rivnut tool ensures the most secure and cleanest installation of brackets, eliminating the risk of loosening over time. While there are alternative methods, this tool provides accuracy and durability.

If you’re unsure about the process, numerous online videos demonstrate these steps in detail, guiding you through the installation from start to finish.

 

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.

 

What are the optional bumper mounting options available?

Optional Bumper Mounting Options

When it comes to mounting your vehicle’s bumper, there are several options to consider, each providing different levels of security and strength. Here’s a breakdown of the choices:

  1. Basic Mounting
    Without additional support, the bumper can be attached using only a single bolt on each side. However, this requires reinforcing the area yourself to ensure the bumper is securely fitted.
  2. Enhanced Mount with Custom Plates
    By using specially designed mounting plates, you can securely bolt the bumper to the trimmed frame rails. This method typically uses two bolts on each side, offering a more stable installation compared to the basic mounting option.
  3. Full Bumper Kit
    This comprehensive kit provides the maximum strength for mounting. It includes:

    • Mounting plates for added stability.
    • Side supports that extend from the frame to the outer edge of the bumper, positioned in front of the wheels.
    • Weld-in frame rail inserts for additional reinforcement.

This option is especially recommended if you are installing an OEM-style bumper and desire the most robust setup.

  1. Frame Rail Inserts
    When you need to modify the frame to accommodate the grill, these inserts are designed to fit directly into the trimmed frame area. Once welded in place, they box in the section of the frame, adding essential structural support.

Consider each option based on your needs, the style of the bumper, and the level of reinforcement required for your vehicle.

 

What is the purpose of ball studs in the conversion kit?

Understanding the Purpose of Ball Studs in the Conversion Kit

Ball studs play a crucial role in the conversion kit designed for specific vehicle models:

  • Support for Hood Pistons: In this kit, ball studs are essential components that ensure your original hood pistons, or struts, function correctly to maintain the hood’s open position.
  • Compatibility with Model Variants: Specifically tailored for the 2011-2016 models, the kit includes four ball studs. Two of these are designed to attach to the hood brackets provided in the swap kit. This ensures seamless integration and support.
  • Adaptability for Other Models: While primarily for the newer models, the kit’s two larger ball studs offer flexibility. They can also be utilized in earlier 2008-2010 installations if larger ball studs are necessary.
Key Highlights
  • Original Fit: Retains the use of original factory fender bolt locations.
  • Installation Flexibility: Provides options to accommodate various installations.
  • Component Inclusion: Ensures all necessary parts are included for effective setup.

This thoughtful design ensures that whether you are upgrading or maintaining, your hood is securely supported using the kit’s comprehensive components.

 

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.

 

What modifications are needed for the windshield wipers during installation?

Modifications Needed for Windshield Wipers During Installation

When installing a new hood on your vehicle, updating your windshield wiper setup is essential to ensure compatibility. Here’s what you need to do:

  1. Update Wiper Cowl and Linkage:
    The existing cowl and linkage in models from 1999 to 2007 must be replaced with a style compatible with either the 2008+ or the 2011-2016 versions. This update is crucial as the original setup won’t fit with the new hood.
  2. Utilize the Existing Motor:
    You can continue using the wiper motor from the 1999-2007 models. This motor can be attached directly to the newer wiper transmission from 2008 onwards.
  3. Adapt with an Adapter or Modify Transmission:
    • Wiper Adapter: Purchase an adapter designed to help attach your original motor to the updated linkage seamlessly, eliminating the need for customization.
    • Manual Modification: Alternatively, you can modify the 2008+ transmission. This involves some grinding to make it fit the older motor appropriately.

Selecting the best approach depends on your preference for ease of installation versus hands-on modification work.

 

What shipping options are available for the conversion kit?

Shipping Options for the Conversion Kit

When you order a conversion kit, we’ve streamlined the shipping process for your convenience.

  • Standard Shipping Methods: We primarily use FedEx Ground and USPS to ensure reliable delivery. If your order is placed before 12 p.m. EST, it typically ships the same day.
  • Address Requirements: Note that FedEx requires a physical address for delivery purposes.
  • Delivery Timeframe: Once your tracking number is emailed to you, expect your package to arrive in approximately 3-5 business days, depending on your location.
  • Order Verification: For orders exceeding $250, a direct signature upon delivery is mandatory. This policy helps protect both parties and ensures your valuable items are safely received.

Take the guesswork out of delivery and enjoy a smooth shipping experience with your conversion kit purchase.

 

What 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.

The versatility of these models means you can install a 2008-2010 or a 2011-2016 front nose (clip) onto any 1999-2007 Super Duty or Excursion. This compatibility expands to various models, including the F250, F350, F450, F550, and the Excursion.

Moreover, if you’re aiming to update a 2008-2010 model to the 2011-2016 look, there’s a specific kit designed for that transformation. This flexibility not only enhances the aesthetic appeal of the older models but also brings a modern touch to the robust lineup of Ford trucks.

 

Is there a kit available for converting between different newer models?

Yes, there is an additional kit for updating the front end from a 2008-2010 model to a 2011-2016 model.

 

What type of conversion does the kit facilitate?

It facilitates a front end (nose or clip) conversion, allowing for the installation of newer model front ends onto older vehicles.

 

What are the specific model years involved in the conversion?

The kit allows for converting the front end of vehicles from the 1999-2007 range using parts from the 2008-2010 or 2011-2016 models.

 

Which specific vehicle models are compatible?

The conversion kit is compatible with Ford models F250, F350, F450, F550, and the Excursion.

 

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