New 71 GS Grill Mounting Problems
by George Nenadovich
I purchased a new reproduction 71 GS grill in Nov of 2007 and just
installed it in Nov 2008. The car I am restoring, 71 GS Stg1...took a little
longer than anticipated to complete.
As of 11-19-08 I was informed by the manufacturer that
the problems described below only happened on the first production run and
subsequent grills do not have this problem.
The grill comes with the mounting studs, one end has 5/16-18
threads(has the "nut" on that end and the other end has coarse
threads that go into the grill. Excellent.....but
Here is the problem......the holes for the mounting studs
are drilled and tapped for the machine threads, 5/16-18....which is incorrect.
The coarse threads will not go into the holes because they are too small.
In order to solve this problem, get a 5/16" drill bit and drill out
the holes. You may need to run the drill bit in and out of the hole to make
is slightly larger than the 5/16" drill bit diameter.
After drilling/enlarging the holes, use a chamfer bit like
the one shown in the tap handle to chamfer the holes. I used a 3/8-16 bottoming
tap to start a couple threads in the plastic hole so the coarse threads
will have something to "bite" into. Place a couple drops of oil
on the coarse threads and then start the coarse end by hand. It is important
to have an assistant watch to make sure the stud is going in perpendicular
to the mounting hole surface....it is very easy to get the stud crooked
in the beginning. Once hand started.....use a 9/16 wrench to gently rotate
the stud. Best to rotate one turn in and then 1/2 turn out to ease stud
installation. Repeat this process for the remaining 5 holes.
Here is the second problem I found....the hole for the headlight
bezel stud/guide pin is too small.
The hole is 0.190" diameter...the guide pin is 0.230-0.240"....use
a tapered reamer
or 1/4" drill bit to enlarge the hole. Otherwise when
you install the headlight bezel it will put too much pressure on the grill
and may cause future problems with cracking.