3rd Gen hidding headlight conversion thread...w/pics of course

[AKcharger]

Guys, wanted to pass on my lessons learned on grill conversion, in short I seriously undersetimated the "pain-in-the-neck-factor" and the amount of time it would take. the final installation took an entire Saturday...but i like it. other notes
- Make sure you get a COMPLETE grill! there are a bunch of brackes and such that are NOT the same as the standard grill
- Make sure it's in good to great condition, since the grill is all pot metal you can't repair it as easy as plastic
- Take the time to do it right

OK lets start with the restoration. I got a '71 set up from a pal, good shape but part of the pax side grill mounts were broke. What I did was get a spacer from Lowes, and JB weld'd it to the grill. it isn't intended to support the weight, just keep it from flopping around.

[AKcharger]

On the headlight bucket it seems like this crack might be common. I was able to get one welded but the other was too bad and had a piece missing. What I did was get an .080 piece of aluminium and make two "doublers" and JD weld them on each side and hold them in place with clamps over night, came out good .

[AKcharger]

I painted all the parts semi gloss black. My chrome was good, if it wasn't pitted it buffed out nice with steel wool.

[AKcharger]

Make sure to pull the bumper to install everything...you just can't do it in the car. here you can align everything up nice. Here I found i was missing a bracket on the top outboard edge...I went to Lowe's and made a construction bracket work with little modification.
Oh, important note!!! do not install the bottom outboard bracket...the bumper will not go on, I found hat out the hard way 

[AKcharger]

Since the car didn't originally have the hide-aways I needed wiring. I raided a local scrap yard for a lengh of headlight harness from a 89 ford station wagon, the advantages are:
- correct gage
- has tracers in the wires to help identification and colors almost match factory colors
- free!
don't forget to test them!

[AKcharger]

The relay is made by Charger Specialties but i didn't see it on their web site so I got it from Paddock for $69. Inside the car use the factory Schematic and/or the instructions that came with the relay, here's what i did:
- For main power to the relay I tapped into the blue ignition wire above the radio
- For power from the headlights instead of going from the switch as shown in the schematic I tapped into the green wire behind the kick panel, much more accessable and does the same thing. I brought the two wires going to the headlight motor through the lil' plastic plug for the clutch rod (if it had one)
- I was able to bolt the unit in under the dash right next to the temp controls

[AKcharger]

When you install bumper you'll need to pull the fog lights to access the outboard bumper bolts and the grill brackets!

[AKcharger]

Finished! I am now an offical expert so let me know if you have any questons

[Nacho-RT74]

hey Bill great job!!!

did you keep the same headlight pedestals what were on the car ?

[AKcharger]

Thanks Sir!
Yes, they are the same, only diffrence is the grille brackets...and the grilles of course

[Nacho-RT74]

OK, my question is because SUPPOSELLY on 71/72 they are different from regular assembly since on parts catalog they list diff headlights pedestal for concelead grilles

[Charger1973]

Good to know.  I still have my 73 headlight buckets and they BARELY clear.  Once the car is done and everything is adjusted properly they might not clear, I dont know yet. 

[Nacho-RT74]

check section 8-34-28 on top, last two items on that section

[RallyeMike]

The headlight brackets for a hidden headlight car are shorter. I think they are about 1" less in height. I have sat them side by side and measured them before.

[AKcharger]

Ok, Ok...man you guys are going to make me blow my secret. There is no trouble with 71-72/73-74 headlight buckets...my passanger fender is a '73-74 and drivers is an original '72. There is zero difference when installing the grilles and such, really the only difference I could see aside from the wheel opening size is in the engine bay there is a bolt hole moved, that's it!

Mike that size difference might be correct, I'll have to check but if it is it's so small I didn't even notice.

Now shhhhhhhhhhh don't tell anyone

[Charger1973]

^^ already knew the secret.  :p

[RallyeMike]

Ok, Ok...man you guys are going to make me blow my secret. There is no trouble with 71-72/73-74 headlight buckets...my passanger fender is a '73-74 and drivers is an original '72. There is zero difference when installing the grilles and such, really the only difference I could see aside from the wheel opening size is in the engine bay there is a bolt hole moved, that's it!

Mike that size difference might be correct, I'll have to check but if it is it's so small I didn't even notice.

I had no idea if the plain jane grill ones would work with the hidden headlight grill, I just know that they are 1" different. 

You really have a 73/4 fender on one side and a 72 on the other? Nobody would probably ever notice it if you didnt say anything, still, I could never force myself to do that !

[Nacho-RT74]

^^ already knew the secret.  :p

me too LOL

anyay the diff is not because the headlights pedestal diff BY YEAR... the difference is BY FRONT GRILLE SETUP just on 71/72 ... regular 71/72 grilles use same 73/74 headliglts mounts

[Nacho-RT74]

BTW, there is another diff between fenders... the way how the splash shield to valance attachs, and its shape... 73/74 is noticeable bigger and covers more. fender have the provision for the bigger shield

[idahogrumpy]

I made this swap to my 73. I used the stock headlamp buckets, no problems. My setup came from a 72 Charger. I pulled the wiring harness and relay from a 78 Chrysler newport as I recall. Everything works great.   Kyle

[BMOTOXSTAR]

All this talk makes me want to styart gutting the 72' set up I have and start the swap. I do not have the wiring so I will just have to use the knob on the headlight motor. That or I will scavenge the junk yards for some Cordoba wiring.

[AKcharger]

scavange the wiring and make it work like its supposed too, you'll be glad you did!

[mikesbbody]

Great job bill! i think hideaways are a part of a charger's identity to me hideaways are a must have 

[ACUDANUT]

 That's the encouragement I needed to do mine. Thanks.

[73SECharged]

This is my 1st post of any kind so bear with me. The headlight buckets or fenders on 73/74's shouldn't be a problem. The answer is on the lower bumper brackets to the frame rails. 71/72 bumpers are much closer to the body than 73/74's, hence the rubber filler strips that a lot of people seem to be looking for. I'm guessing that should make up for the 1" or so Rallyemike mentioned with the different headlight buckets. As for the wiring harness look into the 78/79 magnum's with the clear hideaway's. By shear luck that's where i found mine. I took all of the wiring for the power windows, locks, and trunk release.