I'm not sure what you mean? Clearing the grill didnt cause any gaps or moving anything anywhere we didnt want it....?

There is about 1/2" b/t the bumper and the lowest spot on the headlight which is exactly what you want...so unless your doing 1/2" body lifts, not sure what you mean.

It's difficult to see in pics, but the area of the headlight where the turn signal is drops down a bit, so the minimun spacing for flex is from that point. Also, the fender/fender flare attaches to the headlight a bit higher than the bottom of the headlight (1/4-3/8"). This creates a bit more gap b/t the fender and bumper than b/t the headlight and the bumper, probably about 3/4". If you look at pics of other 05 bumpers, you'll see the same thing, about 3/4 - 1" gap b/t the fender and the bumper and less under the headlight.

The bumper could be moved up from where it is in the pics if someone wanted to. It's sitting at the bottom of the slots. I think looks about right where is is though.

It isnt touching. Even if it were it's made of a rubbery plastic material and stress cracks are highly unlikely in a material like this. It will just flex.

I thinking you are maybe missing exactly how we delt with the grill issue. It really isnt anything magical, but I'd rather not explain.