Sealed beam to composite grill wiring DIY with pics

This procedure is for 1999 Astro
I prefer the composite style grill & headlights so here is the way I went about wiring it in

here is a before shot:


and after:


First get all the pieces you need, grill, headlights with black backing attachment plates, non-functional clear lights that attach to outer edge of headlights, composite left and right pigtail harness from a donor vehicle, and all bolts & screws. I got all my parts from junkyard for around $60.00 total. The swap is a straight forward direct bolt in procedure, no drilling and everything fits, you can find plenty of threads on it. My main concern was the wiring and I couldn't find tutorial with pics for the wiring, so I decided to make one myself.

start with the pigtail harnesses, 2 wires on the left are ground wires I also clipped from donor vehicle


here is the sealed beam plug you will cut off


here is the composite harness ends next to sealed beam plug, notice the wire colors are exactly the same, except the composite style has an extra black ground wire


find a spot to attach your extra ground wire, I chose this spot by the washer fluid bottle since there is no paint under the bolt, I also used the same bolt on the drivers side for the other ground wire


remove bolt


attach ground, it looks almost factory!


run the ground through the headlight bucket and you now have all 4 wires needed to attach the composite harness


cut off the sealed beam plug, and attach all the wires of same color together, for testing


put some tape over the exposed connections and test for high/low and DRL's


if all works as it should, the next step is attaching. I used crimp connectors and heat shrink tubing, I would've preferred to solder the connections but I left my solder gun at work


I attached all 4 wires like this one


then taped them all together with 3M professional grade Super88 electrical tape


then tucked it all in flame retardant plastic wire conduit and wrapped the ends in electrical tape


now repeat process for the other side, bolt everything on, plug it in, and your done