Turns out my problems were caused by my misinterpretation of trhe very first picture in the instructions. Following @Kyle D's correction allowed the hood hinge crossbar and mounts to fit w/o problem.
I’ve run into a problem trying to install the ZZP Billet Hood
Hinges I bought during last year’s Black Friday sale. I have a Hahn
turbo setup and a MadSatd Ultimate Bumper & Grill and the 2 items
end up causing problems trying to install the Zzp Billet Hood Hinge
set.
Looking at Pic #1,
the clamps for the Hahn intercooler protrudes far enough that the ZZP
hinge mounts do not place the stock Polaris hinge crossbar low enough
and in front of the intercooler clamps. I had previously installed
the MadStad (now Twist Dynamics) Hood hinge set which used the
original stock mounts and placed the hod hinge crossbar in the
correct position.
Looking at Pic #2, I
placed the stock mount next to the ZZP mount and as can be seen, the
ZZP hinge locates the stock hood hinge crossbar further back than the
stock mounts, resulting in interference with the Hahn intercooler
clamps.
Looking at Pic #3,
the higher positioning of the ZZP mounts hood hinge crossbar means
the front strut hits the rear strut.
With pressure, it looks like I
can get the rear of the ZZP mount to line up with the frame mounting
hole, or I think I could once I can get around the positioning issues
caused by the MadStad Ultimate Bumper brackets (Pic #4).
As Pic #5 shows, the
ZZP mount is basically at the rear of its slot because the MadStad
Bumper bracket doesn’t allow the ZZP mount to be any further
forward.
It looks like I need to remove some of the lower front edge
of the ZZP mount and the forward edge of the rear bracket foot to
clear the headlight mounting crossbar to clear the TD Bumper bracket
and also need to extend the mounting slots in the ZZP mount so they
go farther back and allow the stock hood hinge crossbar to clear the
intercooler clamps (Areas that I think need removal/extending marked
with Green lines). This would also place the latch bolt a little more
forward of its current positioning (see Pic #6),
but there is enough
room to move the stock latches forward to allow the latch bolt to
engage the front hood latches.
Removing this extra
material will not be an easy task as I don’t have any metal milling
tools/capability and will probably need to just drill holes and then
file everything smooth or use a saw to cut away material/extend the
slots (not necessarily any easier since the mounts are so thick). Either way will be a PITA. I’d really like to use the ZZP
Billet Hood Hinges since they don’t require a gas cartridge for
proper operation.
Has anybody else run
into this situation or have any suggestions on getting everything to
fit w/o doing a lot of machining/filing?
My Daughter thinks I should try using the stock brackets first to see if I can get things to work w/o a lot of difficult work, but I'm not sure how the stock mounts might affect the hinge geometry and opening range.