Next image shows the current fit. I have elongated the four lower mounting holes so the grill shifted about 3/16" to the PS. The upper mounting holes look like I can get the screws in. The grill is injection-molded and the cross-section is probably .125" to 150" so I'm thinking that if I receive the back side 1/16" where it seats on the sheetmetal... that might bring that lower edge in just enough. Plus... I guess I could very carefully sand the knife edge off and fair it in if I need a little more. Messing with 50 year old sheetmetal that's already painted is out of the question.
Opinions on what might work best, and could I use a heat gun to sort of push the sanded edge tighter if there's a gap? I'd hate to countersink a screw there to tag it to the fender "nose" because I'd have to repeat it on the opposite side and bottom line is it wouldn't be authentic. TIA for any/all advice.-Mike