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Old 02-24-2012, 07:37 PM   #1
AWD.riven
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Default DIY Walkthrough 02 Bugeye Front end to 04 Blobeye Conversion

Okay, so I couldn't find any walkthroughs on how to do the front end conversion so I figured I'd try to tackle it myself and do a write up for anybody trying to do it in the future. The actual conversion is not that difficult. It is a very time consuming and tedious process. Set aside a weekend or so to do it because it is about a 10-15 hour process to complete. Took me about 8 hours but I had two friends helping.

Things you need:
Ratchet set (you really only need 10 and 12mm sockets for the whole thing)
Small Ziploc baggies to hold all the bolts seperately
High Powered drill with a medium sized drill bit (also a good idea to have a few backup batteries)
Mig or Tac Welder (there is an alternative to welding which will be outlined)
Basic hand tools
A grinder comes in handy sometimes; Although is NOT needed. This isn't a hackjob walkthrough.
Jack and Jack stands, from autozone is fine.
Large Clamps
Spotlight or Flashlight of some kind
Chisel or Prybar with handheld hammer or sledgehammer

Step 1: Remove Hood
There are 4 bolts holding the hood, should be 12mm bolt. Helps to have somebody hold the hood while removing the bolts. Also remove the windshield washer fluid lines from the hood, they can be difficult not to break so if you squeeze them while taking them off should make it easier.

IMG_1329 by AWD.riven, on Flickr

IMG_1330 by AWD.riven, on Flickr

Step 2: Remove Headlights
Very easy, remove the bolts holding it onto the upper core support then also the core support arms.

IMG_1340 by AWD.riven, on Flickr

IMG_1343 by AWD.riven, on Flickr
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Last edited by AWD.riven; 02-24-2012 at 09:22 PM.
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Old 02-24-2012, 07:37 PM   #2
AWD.riven
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Step 3: Remove Fenders
This is much easier said than done and can get very frustrating, to start; take off the bolts holding the fenders to the chassis located in the engine bay area.

IMG_1332 by AWD.riven, on Flickr
When unbolting these be mindful, they are old bolts and may strip from the underneath weld they have holding from underneath, then you’ll end up having to cut the tops off.

IMG_1347 by AWD.riven, on Flickr

Open the door and use a deep well socket to remove both bolts holding the fender to the door jam.

IMG_1333 by AWD.riven, on Flickr
Remove the wheels and fender liner, the clips are an absolute pain in the ass to remove. I had no plans on putting it back so just decided to tear it out..

IMG_1339 by AWD.riven, on Flickr
Remove the bolt holding the bumper to fender, then just remove the bumper in general. It shouldn’t be many more bolts to get it off.

IMG_1338 by AWD.riven, on Flickr
Remove the bolt under the side skirt, you can remove the whole skirt but I just decided to take the single bolt on holding in the fender.

IMG_1337 by AWD.riven, on Flickr
IMG_1338 by AWD.riven, on Flickr
Remove the fenders, That should be all the bolts to get both fenders off.

IMG_1344 by AWD.riven, on Flickr
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Old 02-24-2012, 07:38 PM   #3
AWD.riven
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Step 4: Take a Second
Take a second to re-evaluate everything and make sure you have all the bolts in the bags and make sure you have everything away from the car as far as the old parts. Clean up your space, this is one of the most important parts as it keeps you organized and working more efficiently.
This is where you should be at.

IMG_1348 by AWD.riven, on Flickr
Step 5: Unhook you’re A/C lines
Be careful when doing this; when you unbolt your lines it will shoot off and blow free-on in your face if you aren’t careful.

IMG_1350 by AWD.riven, on Flickr
Step 6: Drill out the old core support
Many people will just cut up the core support and weld in the new one, I opted for the cleaner correct way to do it. Drill out all the old spots welds. Just put the drill bit right on the spot weld and drill, it is very taxing and time consuming. This is where it gets difficult and is in your best interest to pay very close attention and watch EXACTLY what we are eliminating and drilling.

IMG_1351 by AWD.riven, on Flickr
The holes I have circled are welds that have been drilled out
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Old 02-24-2012, 07:39 PM   #4
AWD.riven
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IMG_1361 by AWD.riven, on Flickr

IMG_1353 by AWD.riven, on Flickr

IMG_1354 by AWD.riven, on Flickr
The lines are showing the next step..

IMG_1355 by AWD.riven, on Flickr
Each side, drill out just the lower arms of the core support that are welded to the frame. They are circled, this needs done on both sides and also in the middle. I forgot to take pictures of that. Then after you complete drilling out all the welds it WILL NOT just come out, you need to take a chisel or pry bar and put it in between the core support and the chassis and separate the two. The lines are pointed to show an illustration of it.

IMG_1357 by AWD.riven, on Flickr
You can see the center where I have circled of the center arm welds of the core support. There are 3 and kindof hard to get to.

IMG_1358 by AWD.riven, on Flickr

IMG_1360 by AWD.riven, on Flickr
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Old 02-24-2012, 07:39 PM   #5
AWD.riven
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Step 7: Repeat this process on the core support you have to replace it with. Yes, drill out every spot that you did and split it from the lower pieces housing under the headlight.
Step 8: Line up the new support
Line up the new support to the holes near the top EXACTLY to the drilled out holes, Then use clamps to clamp it down while welding.

IMG_1368 by AWD.riven, on Flickr

IMG_1369 by AWD.riven, on Flickr
Step 9: Weld in the new support
Here is where you have the option of bolting or welding. Bolting it will not be a structurally sound as welding. Get heavy duty bolts with nuts for underneath and heavy screws to drill into spots with a back you can tap into. I chose to weld.

IMG_1371 by AWD.riven, on Flickr

IMG_1365 by AWD.riven, on Flickr
Step 10: bolt back up the A/C and airbag sensors (I think is what they are haha)

IMG_1373 by AWD.riven, on Flickr
Step 11: Reverse
Reverse all the steps and bolt everything back up and enjoy!
If anybody has any questions feel free to pm me or add to the walkthrough, figured it’s better than nothing.
Finished Result:

IMG_1423 by AWD.riven, on Flickr

I’m sure I’ve forgotten some stuff like the hood latch and horns ect ect. But I would hope this is suffiecient for a general outline, Would’ve definitely helped me when I did this to have an outline.

419380_3536203726486_1314124802_3511740_467857915_ n by AWD.riven, on Flickr


431320_3536203486480_1314124802_3511738_1685270476 _n by AWD.riven, on Flickr

Last edited by AWD.riven; 03-18-2012 at 06:58 PM.
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Old 02-24-2012, 08:55 PM   #6
25rsti
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Gotta love those clams!! haha jk

Great job. Looks awesome!
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Old 02-24-2012, 09:21 PM   #7
AWD.riven
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^ hah thanks man, it actually wasn't as hard as you would think. The headlights I just had a performance shop wire them. Cost 150 bucks compared to 1900 just to do the conversion.
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Old 02-25-2012, 01:21 AM   #8
RL206
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Right on, this is something I have thought about alot, but I have kept it on the back burner since I'm not sure how long I'll have the car, Sonic Yellow on a 04-05 front clip would be crazy, I've only seen one on a sedan though.

Anywho, congrats and good job, looks fantastic.

Mind doing me a favor and adding a shot from the side, specifically where the fender and bumper meet at the wheelwell?
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Old 02-25-2012, 05:50 AM   #9
AWD.riven
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Quote:
Originally Posted by RL206 View Post
Right on, this is something I have thought about alot, but I have kept it on the back burner since I'm not sure how long I'll have the car, Sonic Yellow on a 04-05 front clip would be crazy, I've only seen one on a sedan though.

Anywho, congrats and good job, looks fantastic.

Mind doing me a favor and adding a shot from the side, specifically where the fender and bumper meet at the wheelwell?
I blew a coupler off my fmic so it's not lined up perfectly but when it's done I'll update the thread with more pictures.
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Old 02-25-2012, 11:29 AM   #10
baldwooky
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seems like an awful lot of work to make your car uglier.

BUGEYE > all
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Old 02-25-2012, 05:38 PM   #11
AWD.riven
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Quote:
Originally Posted by baldwooky View Post
seems like an awful lot of work to make your car uglier.

BUGEYE > all
Says the one with a two tone paint wagon. this is a walk through for anybody who needs help with this conversion because alot of people prefer the 04 front end.
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Old 02-25-2012, 07:01 PM   #12
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awesome build.. when i did me 02 to 07 i just changed the upper rad support. ur car looks great.
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Old 02-25-2012, 07:40 PM   #13
AWD.riven
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Quote:
Originally Posted by 1VIPWRX View Post
awesome build.. when i did me 02 to 07 i just changed the upper rad support. ur car looks great.
Thanks man, yeah there are tons of different way but I didn't cut not one piece and I didn't want to hack it up. When you cut it the support has the be cut THE EXACT same on the one you're putting in as well as the old one.
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Old 02-25-2012, 08:00 PM   #14
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Great write up! should be sticky'd! Looks great
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Old 02-25-2012, 08:05 PM   #15
AWD.riven
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Quote:
Originally Posted by jakechup View Post
Great write up! should be sticky'd! Looks great
Thanks dude! Part of the reason I did it myself was to write this to help other people on the future doing it.
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Old 02-25-2012, 08:05 PM   #16
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So question of the day for me is: how expensive is the core support for the 04/05?

I ask this because the Chargespeed conversion kit for this conversion is $270 bucks, and lets you use your Bugeye core support following some minor modifications.

Last edited by Smurftastic; 02-25-2012 at 08:18 PM.
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Old 02-25-2012, 08:19 PM   #17
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Please tell me you had something covering the windshield!? Nice write up.

PS a spot weld drill bit is nice because it will not go through the second layer of metal.
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Old 02-25-2012, 08:29 PM   #18
AWD.riven
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Smurf, the chargespeed conversion kit they no longer make to my knowledge. I have looked into those but I was afraid it wouldn't line up right and I just don't like the idea of that. The core support is pretty cheap, you're best off to buy a full clip like I did.

Matt, no I didn't have anything over the windshield. I'm missing why exactly I should have anything over it. Windshield is still perfect.
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Old 02-25-2012, 09:00 PM   #19
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Grinding/Welding sparks easily pit glass.
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Old 02-25-2012, 09:07 PM   #20
AWD.riven
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^ makes sense, the shards would fly up on windshield. Guess I'm lucky then hah
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Old 02-27-2012, 01:56 AM   #21
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What do suggest for someone who wants to do the swap but doesn't know how to weld and doesn't have the equipment? Find or pay someone who knows how or do you have something else in mind as an alternative?
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Old 02-27-2012, 06:35 AM   #22
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^ pay somebody to weld it and wire up the headlights. 100-150 to wire the lights and no more than 200 for somebody to come to you and weld it. Or you could bolt it in where the welds are. I wouldn't but it's an alternative.
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Old 02-27-2012, 11:36 AM   #23
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Quote:
Originally Posted by AWD.riven View Post
Says the one with a two tone paint wagon. this is a walk through for anybody who needs help with this conversion because alot of people prefer the 04 front end.
Then why'd you buy a bugeye in the first place?
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Old 02-27-2012, 11:57 AM   #24
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Quote:
Originally Posted by EvilCerealBoX View Post
Then why'd you buy a bugeye in the first place?
Because I got a good deal, I don't have anything against them bugeye's are awesome but I love the 04-05 look and I just found it humorous to see somebody talking crap with a two tone paint job.
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Old 03-18-2012, 06:58 PM   #25
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