[screamin_c10]

So one inherent issue with the 67-68 Cougars is the grille and headlight door assembly. They look cool as hell and are an iconic feature of the car, but the design sucks... The doors way a ton and are vacuum operated with spring tension to close them, a recipe for disaster. The frame is pot metal with very little support. Do a Google search and I bet every 67-68 pictured will have sagging doors. I have found literature from 1967 showing the doors misaligned from the factory.

OK I'm off my soapbox now...

The fix... First the headlight doors needed an upgrade into the era of electric actuators. A common swap consists of Miata or Probe motors so I hit ebay and cooked up this setup: