2005 Chevy Colorado Front Fascia On A Chevy S-10 - Ultimate Update

8.To build the new radiator support, the pieces that compose the final assembly had to be mocked up. This allowed Devious to make provisions for all the mounting tabs and ensure that everything lined up correctly. Notice the tape on the headlights and grille, as well as the tape holding the headlights. It's a good thing to only buy parts once. Scratched plastic sucks.

9.The first few tubes of the radiator support were built off the center hoop. The center hoop is where the radiator will be mounted, so it was constructed first, followed by the bent tubing that will allow for the fender, headlight, and grille mounting.

10.Making sure everything stayed square, the fenders were bolted to a cross strap that was tack-welded to the radiator support hoop. This will ensure that the front end stays where it's supposed to and the final results are perfectly fitted.

11a.Continuing along, more tubes were added to the main hoop to allow everything to be bolted up with maximum support. Other tubing was added to allow the lower fenders to be bolted up and the whole radiator support to be a bolt-on affair.

12a.Throughout the process of building the radiator support and mounting assembly, fitment was checked to make sure everything was going according to plan.

13a.It was time to give the truck a front bumper once again. Notice the wood blocks on the floor. They're just tall enough to allow the bumper to sit on them at the height needed to build bumper brackets.

Since the front-end conversion is going on a truck that was never designed to look this way, Devious went beyond the call of duty and custom-built a lower valance for the Colorado bumper being used. Steel wings were first fabricated on each side of the bumper.

A closer look reveals the lower lip, which was added to give the front bumper a more designed appearance. Cleco pins held the pieces of sheetmetal in place while the front bumper was being built.

Once completed, the new pieces that make up the lower half of the Colorado front bumper were welded to the upper half of the Colorado bumper, making it a single unit. That, friends, is how you teach an old truck some serious new tricks.