Index

• Factory Documentation
• Grille Design
• Other Related Changes
• Chronology
• Conclusion

Introduction

This research is about the change from a chrome-highlighted grille for the 1968 Rally Sport (RS) to a black grille at the end of May 1968. (Note: the term chrome is used to denote the material used to give the chrome / silver highlight on the horizontal bars of the RS grille). The research started with a post on the CRG Forum, and after more than two years of research of known original cars, parts manuals, and original 1967 and 1968 RS grille blueprints, it is time to pass on the findings.

The data collected shows that the 68 chrome grille was used in regular production on the Rally Sport until the later part of May 1968. To date, the data shows some 05D and 05E RS/SS cars with a black grille, and some with the chrome grille, indicating a transition period during the last two weeks of May.

Early 1968 Camaro RS/SS Publicity Photo with "Chrome" Grille

Early 1968 Camaro Rally Sport Publicity Photo with "Chrome" Grille

It's still not clear just what prompted the change. Perhaps Chevrolet was looking ahead to the black 69 RS grille and wanted to institute that new look in post-May 68 models. Or perhaps they wanted to revert back to the black 67 RS grille style. GM currently makes only the black grille and has been doing so for service parts from the end of the 68 model year to the present day.

Later non-chrome 1968 Rally Sport Grille

Factory Documentation

Camaro Factory-Installed Optional Equipment - January 1968

The January 68 Model Options description (highlighted in blue above) states the Camaro SS features, but there is no mention of the grille. However, an April 22, 1968 description of those same Camaro options (highlighted in blue below) notes a black accented grille on the SS.

Both descriptions list the same RS features, simply stating that it "Includes special grille....".

Chevrolet Motor Vehicle Price Schedule - Vol 2 - Revised April 22, 1968

Grille Design

GM has always manufactured the grilles and it is produced today using blueprints that originate from the 67 design. In fact, the 68 grille blueprints refer back to the 67 prints for design specifications and other information such as the required color/shade of black for the ABS plastic. One of the most interesting discoveries was that none of the original GM blueprints examined had any notation regarding chrome or the placement of chrome on the grille.

There is a design difference between the 67 and 68 RS grilles. On a 67 grille, the horizontal and vertical bars are the same height. On a 68 grille (and headlight doors), the horizontal bars extend about 1/16 " to enable the application of the chrome to the horizontal bars. The 67 RS grille was only available for service during the 67 and 68 production years before the 68 grille was used for both 67 and 68 applications.

Close-up of 67 RS grille

Close-up of 68 RS grille

Note that the center grille assembly is comprised of three parts: the "lower grille", "center grille", and the "upper grille". See the 1968 Camaro Assembly Instruction Manual (AIM) page that illustrates the assembly. The individual parts were assembled at the assembly plant. The complete center grille assembly was available as a service part.

The 68 service parts were probably the same as the production parts. So the 68 service parts were probably chrome up to the May 68 timeframe and then supplied as unchromed from then on. To that end, the below picture shows one of two observed "new in the box" service grilles which are black. If a 68 chrome grille needed to be replaced and a NOS chrome grille was not available, the replacement black 68 grille would have been painted to match the original chrome doors. The first "Note: paint as required" is found no earlier than October 1968 for the headlight covers. So far, December 1971 is the earliest such a note is found for the center grille.

1968 Rally Sport Service Grille

Today, the chrome grille is being made by suppliers who purchase the black grille from GM and then add the chrome. The chroming process used on the original 68 center grille is thought to be a process called metallizing (the process has been improved on from what was used in the late 60's). Reportedly, the current suppliers of the chrome grille are using a hot stamp process and the appearance is not equivalent to the original "chrome".  

Other Related Changes

The 68 RS headlight doors have a mold cavity number on the back side. The left (driver) side is usually number 1 and the right (passenger) side is usually number 3 (see "3", rotated counter clockwise, molded in the center of cover below). However, on some of these original cars it was noted that several of them had a mix of original 67 and 68 headlight covers. There are no mold cavity numbers for the 67 covers but instead they have part numbers on the back side. Apparently with the changeover to the all black grille, the 67 covers (with the part numbers molded on the back side), were utilized on the late year 68's. It is speculation only, but this may have been necessary as a shortage of black 68 headlight covers may have existed or perhaps a way to reduce leftover 67 cover inventory.

Rally Sport Headlight Covers (Rear View)

The backing plate assembly (which holds the headlight cover) also appears to have changed in the late May timeframe. The left picture below is the earlier version, the right picture is the post-May version. (It should also be noted that the backing plate has some adjustability via the caged nuts to aid in aligning the headlight covers to the center grille and the the outer bezel.)

Rally Sport Headlight Backing Plates

Some of the hardware used on the grille/front end appear to have been changed around the same time as the grille change. The hardware changes involved nuts, washers, and screws (see the change noted to item 8 in the AIM and the pictures below). Note that the nut (#8) was replaced with a U-nut attached to the lower grille in observed 05D and later cars (another change from the AIM illustration).

1968 Camaro Assembly Instruction Manual (AIM), Z22 page A4

Attaching Details: Note the screw is inserted from the bottom which differs from the AIM illustration.

Part number 9419303 screw and 9422836 nut found on later (after 05D) RS cars

Grille Rivets

The original rivets (part #4 in AIM) that held the center grille to the upper and lower grilles have played a major role in determining the originality of the grilles investigated during this research. The original rivets were anodized aluminum and dull black. They measured 3/16" x 17/64" x 14/32" and were a semi-tubular rivet. The rivets were actually waxed with a product called Fabrilube to help with the installation. (These rivet details were supplied by AMK products in Winchester, VA who have the original GM manufacturing spec's for these fasteners.)

Note that a center grille assembly service part may also have the original style rivets. So the presence of the rivets is not definite proof that it's the original grille, but the lack of the rivets (i.e. presence of bolts or pop rivets) is proof that it's not original.

Chronology

Conclusions

We are still collecting car data to help support the conclusions presented here. And while we have not observed any difference between the LOS and NOR assembly plants, we again would like more data to confirm this. We would greatly appreciate anyone who has an original grille or original headlight covers to contact us with the data from their car.

Acknowledgements

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