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DIY stock to "aftermarket" grill

22K views 34 replies 25 participants last post by  flylow 
#1 · (Edited)
DIY stock to "aftermarket" grill ***finished

This is at your own risk as with any DIY

If someone gets stuck when attempting this:
my cell is: 405-361-five-eight-five-eight
I can try to help the best i can

Needed:

-screw driver (one that angles at 90 degrees helps)
-metal mesh or plastic grating
-bondo **(i found the epoxy bondo, comes with black epoxy and a clear/white hardener, worked much better than the standard chalky car bondo)
-dremel
-file
-Breathing masks
-sand paper
-screws (if making temporary grill)
-firm but agile grip
-patience and ingenuity
-spray enamel

Time: however long it takes you to get it perfect


First take your screw driver and remove six plastic scews and two plastic screws on the bumper right next to the tab sticking up by the headlight



Now remove the six screws on the back holding the grill to the bumper



Being very careful not to break any tabs like i did (dont worry though the other 5 will suffice)



Since i'm taking my time i decided to make a temporary "grill" while i whittle away at the stock one.



Just trace the stock grill on some chicken coop fencing or w/e and trim to fit taking note of the hood latch to make room for it. I then cleaned up and painted the mesh white.



temporary mesh replacing grill.



continued:


Cut carefully around the inside of the grill noting where the tabs and screw holes go into the bumper so as to not cut them off. I left two tabs on the bottom as accents. I also went to lowes and grabbed some expanded metal as the grill insert. Now to touch up, trim, and sand before it goes to paint and installation hopefully tomorrow.




A mock-up of close to what it will look like once finished.



After my friend left that coxed me into leaving the bottom tabs there i found them extremely tacky and removed them. If you look close you can see holes in the grill where the inserts used to be. For this i called on bondo. I found an epoxy mix that bonded well. Mix, cover, and sand until you feel it's "good enough". Final Prep and paint today.



After prime/base/clear. The grill was held to the grill piece with epoxy and 3 small clips. With better supplies i could have made it look much better.



Grill finally attached to car



Sorry this took so long guys. My national guard unit messed up orders and i got called in for two weeks of Active Duty two months early.
 
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#2 ·
Have to say, I like it just for the simple facts of, it fills a need, and your doing it yourself!
 
#4 ·
I'm taking it you found the mesh? I used chicken wire on my other cars, just sprad it with plastidip so it wouldn't rust. Looks good so far!! Can't wait to see the finished producted.
 
#9 ·
Good job, looks great rather spend 100 bucks or 200 for CF but that's just me. GREAT write up +1


Sent from my Autoguide iPhone app
 
#12 ·
:shock: WOW!!!!! That looks amazing for a DIY, congrats man, think I may go this route instead of shelling out 250+.

:gc-drool1::bowdown:

Oh what filler did you use to bridge the gaps where you cut the factory plastic?
 
#14 ·
This is a definite DIY, much better than burning $200+ lol
 
#16 ·
Good writeup.

I attempted something like this, but have never used bondo before, so I didn't think to fill in the holes resulting from cutting out the center section. I ended up trashing the whole thing and getting an RMR carbon fiber grille instead, but I should have gone your route and saved myself $$$.

Well done!
 
#17 ·
bondo is simple my friend. Mix, set, and sand.

I did this because i like doing projects on my car and have the patience to do so. I would strongly suggest anyone who attempts this, has the mindset and pocket money upon either hating their work, becoming much to impatient, or breaking the grill to buy an aftermarket grill as you have done here.
 
#18 ·
Its also forgiving like working with metal. You take too much off, you weld some more in and start over. Same with bondo, sand to deep, mix it up and start over.
 
#23 ·
excellent work! great final product. I may do this if i cant afford a front grill in 30 days because the car needs a different grill from the factory and im sick of looking at it lol. thanks op!
 
#25 ·
Looks good. I just did the lower section of my 13. Black alum mesh off ebay for like $20. Also found it easier to just pull off the whole front fascia than to try and fight screws and clips at awkward angles behind it.
 
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