Brow bar install questions

[TTait]

We are looking to finally install a pair of brow bars. Following the write up in the how to section and I have two questions:

Why do I have to remove the headlight buckets? It seems like the bar will go in place fine without removing them.

Is the bar supposed to slide fully forward all across the width of the opening, seems like it will not. I have rectilinear bars with no cut out supplied a few years back from Henniger. Can I use them as is or do I need to relieve them to get them all the way forward?

Thanks all.

Tom & Mei

[Mark D]

If you're trying to get the bars slid in all the way forward you either have to round off the outboard corners to match the curve of the fascia, or you will have to slide the bars further towards the center of the car. I rounded the corners off until each bar looked something like this:

http://dmctalk.org/attachment.php?attachmentid=30000&d=1407763678

3M Window Weld seems to be the popular choice for adhesive.
http://www.amazon.com/3M-08609-Window-Weld-Urethane-Cartridge/dp/B000FW61EW/ref=sr_1_1?ie=UTF8&qid=1407763743&sr=8-1&keywords=3m+windo-weld

I used this adhesive on my (aluminum) eyebrow bars around 3 years ago and they are still holding strong. I also pulled the fascia completly off the car so I had better access to install the bars and make sure I only got the adhesive where I wanted it. Before gluing in the bars I used a heat gun and reshaped the fascia by hand so it was nice and flat. After installing the bars I used wooden paint sticks wrapped in tube socks to protect the fascia paint and clamped everything together and let it sit for 24hrs.

A lot of people have installed the eyebrow bars with the fascia on the car, but for how expensive it would be to replace if you screw something up I opted to remove it so I was able to prevent any expensive "oops" moments. It was also a good opportunity to remove and repair any rust on the headlight brackets, rock screen, fascia brackets, replace hardware with stainless, etc.

[Flash66]

A better adhesive for this is Panel 60 which is the same resin based epoxy that is used to fasten the studs to the fascia and front spoiler. Will hold up way better than window weld and much easier to work with. It's also paintable. Panel 60 Valvoline plio-grip

http://www.amazon.com/gp/aw/d/B0082LGBL6?pc_redir=1407418722&robot_redir=1

[Delorean Industries]

Did you find a local source after our discussion?

[Flash66]

Did you find a local source after our discussion?

Sure did Josh. Found it at a body shop supply house in Vegas. Really great stuff, and excellent workability. Thanks for the tip on a perfect solution!

[TTait]

looks like a 2 part epoxy... Is the applicator designed so it can be used multiple times? At about $50 a pop it would be nice if I can re-use it multiple times.

I already have the 3M. Never heard a complaint about it. Is the 3M considered perfectly acceptable and the panel 60 a super premium product that is nice to have, or do I really need the panel 60 (opinions will vary - I know).

Thanks for your help guys.

Tom