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Old 07-19-2009, 12:22 PM   #1
thrasher
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Question I Need NASIOC's Input on DIY Grille - Opinions/Advice Welcome

SEE POST #49 FOR THE FINISHED PRODUCT

I've been running an Outback Sport grille on my bugeye for a couple years now, and I'd like to have another grille so I can change things up once in a while. I've always loved the UK Prodrive STi Edition front end, and I thought I might try to modify my OEM grille to that style.

Here is the look I'm attempting to reproduce:


Here is my progress so far:

OEM honeycomb grill


Starting to remove honeycomb with hacksaw blade and crappy Harbor Freight "dremel" tool


Honeycomb removed - still a long way to go


Here is a close up of the spots where the honeycomb formerly connected with the outside portion of the grill - rough sanded only for now


This is the point I'm at now - tabs in lower corners need to remain so the lower clips still connect




And here is a test fit just to help determine next course of action


My thought was to use some sort of body filler to complete the lower pedestal below the badge, sand everything well, prime, and paint it WRB. Then I would use black GutterGuard to create the mesh in the back. The only issue with that is that the actual Prodrive Edition grille has the badge flush with the front and lower, and the OEM grille has the badge slightly recessed, tilted back, and centered.

My questions are:
1) What is the best/easiest material to use to complete the pedestal beneath the badge? I am no auto body specialist, so I'd like to work with something fairly straightforward.

2) Should I bother trying to move the badge forward and down, or just leave as is and see how it turns out?

Thanks in advance for your comments/advice.

J

Last edited by thrasher; 08-08-2009 at 05:46 PM. Reason: took some better pics outside
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Old 07-19-2009, 07:29 PM   #2
SLI99
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leave the badge where it is and just clean up the plastic......looks sick
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Old 07-19-2009, 07:51 PM   #3
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will the top piece of the badge pillar fit in front of the lower piece right under your badge? it might push that part out enough to give you the "flush" look you're going for. of course you'd have to clean it up a bit but it would be more sturdy than just body filler i think.

looks great!
cant wait to see the end result.
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Old 07-19-2009, 08:05 PM   #4
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leave it where its at. i like it. paint it to match though
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Old 07-19-2009, 08:06 PM   #5
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Nice job all around, grill, lights, lip, etc. BTW, what brace is that in the lower air intake area?
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Old 07-19-2009, 10:40 PM   #6
thrasher
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Quote:
Originally Posted by Mobutusan View Post
BTW, what brace is that in the lower air intake area?
Thanks! Its a CUSCO brace. Someone on here made a comment one time that if there are two bolts on your car, CUSCO makes a brace to go between them. Its so true. I can't imagine it has much (if any) positive effect for a street car, but I really like the way it fills the lower grille area. Install was easy once the bumper was off, but it requires custom cutting of the bumper to fit. I freehanded it with a razor knife, and I was actually amazed how well it turned out.

Thanks to everyone else for your input.

I guess I'll leave the badge where it is, and just use body filler to clean up the area beneath it. Anybody have any advice on what kind of filler I should use?

J
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Old 07-19-2009, 10:51 PM   #7
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nice job man
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Old 07-19-2009, 11:00 PM   #8
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here is an option cut the center emblem out....trim the bottom of piece behind the emblem so it curves with the bottom of the grill and use jb weld to glue it together and then go with the gutter guard on the back.....


plus my grill doesnt have those to bottom tabs since the bodyshop broke them while putting the grill on.....and it has held fine with the top tabs for about 2 1/2 years and it doesnt rattle either!!!!
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Old 07-20-2009, 09:38 AM   #9
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looks good so far. cant wait to see the finished product. good luck man!
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Old 07-20-2009, 04:30 PM   #10
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I just read a thread about this. Do a search, the guy figured out how to move the badge down and fiberglassed it there.
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Old 07-20-2009, 04:44 PM   #11
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Nice work, should come out pretty good!
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Old 07-20-2009, 04:55 PM   #12
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looks great, except get rid of the grille remnants below the subaru badge and your golden!

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Old 07-20-2009, 05:25 PM   #13
thrasher
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Quote:
Originally Posted by JackTheMetalHead View Post
looks great, except get rid of the grille remnants below the subaru badge and your golden!
Thanks. As I said in my OP, I will apply body filler below the badge and then sand it smooth, so now "grill remnants" will be visible. Then the entire grille will be painted WRB. Its a work in progress.

J
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Old 07-26-2009, 09:04 PM   #14
thrasher
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Default Made a little progess today...

Before you read this and jump to a ricey conclusion, please note that the grille mesh will be painted BLACK!!!!

I was finally able to make some progress on this thing. I've read most (if not all) of the previous DIY grille threads, and almost everyone attached the mesh to the back of the grille with hot glue or liquid nails or something gooey. When I noticed an existing channel running behind the top of the bumper, a light bulb went off above my noggin, and I decided to try something new...I wanted the mesh to attach behind the grille and remain completely separate from the grille itself.

I got my Gutter Guard mesh from Home Depot - see below




Then I made some rough measurements, and trimmed the mesh with tin snips. The mesh has a natural curviture to it, which sort of works to my advantage in this case.

After a couple trial-and-error fitments and additional trimming, here's what I ended up with


Here is where I trimmed around the clips where the lower portion of the grille attaches to the headlight


And a little extra trim around the hood latch


And here is the hacked up grille clipped in place. Seems to fit really well!


Next step was to apply the first coat of paint to the mesh. As you can see, I used generic flat black auto paint from Advance Auto - nothing fancy required


Pizza box FTW!!!


Next steps are to:
1) Finish painting the mesh black
2) Apply body filler beneath the badge and sand the entire grill smooth
3) Prime the grille for paint
4) Paint the grille WRB
5) Hopefully revel in my success

Last edited by thrasher; 07-26-2009 at 09:34 PM.
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Old 07-26-2009, 10:45 PM   #15
apkarian100
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Nice work, I just used the same gutter guard for my mesh for my grill, but again, I also need to paint it black:

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Old 07-27-2009, 12:40 PM   #16
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It looks good man!
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Old 07-27-2009, 01:01 PM   #17
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very nice.

Last edited by bbun; 07-27-2009 at 03:43 PM.
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Old 07-27-2009, 03:40 PM   #18
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Nice work, if I had a bugeye I would be following in your footsteps.
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Old 07-27-2009, 04:16 PM   #19
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that is a very nice DIY grill. I have been thinking about what to do with mine and i really like how yours is coming out, i may do the same thing. Can't wait to see the finished product.
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Old 07-29-2009, 09:28 PM   #20
thrasher
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Default More Updates...

I had some free time tonight to do some more rough cutting/sanding and test fitting.

I've been adding a coat of black paint to the mesh each night this week, so that should be good - here it is installed


Here you can see where the mesh sits in relation to the bumper


Even though it is not what I originally set out to do, I think I am going to leave the grille like this with the badge centered instead of moving it down.

Since I am not a body shop guy, I just know that adhering the badge to the bottom of the grille and adding body filler around it to make it look like the Prodrive grille will either (a) take me a year and a day which I don't have or (b) look like dogcrap.

So here are the grille and mesh installed together




So my plan was to still paint the grille WRB - does anyone think I should paint it flat black instead? Would anyone be willing to photoshop the grille WRB so I can see what it might look like?

Thanks for checking in.

J
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Old 07-29-2009, 09:33 PM   #21
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Looks good!

I'd go for Flat black personally, but I'd like to see the WRB photoshop before I decide.
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Old 07-29-2009, 09:34 PM   #22
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How strong is the piece holding the badge? Is there any flex?
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Old 07-29-2009, 10:00 PM   #23
thrasher
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Quote:
Originally Posted by WRX USA View Post
How strong is the piece holding the badge? Is there any flex?
The badge is actually pretty secure. However, there is some flex between the top and bottom portions of the outer ring. Its hard to tell in the pics, but the bottom of the grille droops slightly now that there is no pillar connecting the badge to the top. Its not a big deal - when I'm done painting I'll just add something as a spacer beneath the grille to lift the bottom up some.

J
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Old 07-29-2009, 09:37 PM   #24
*Farley*
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Looks Good
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Old 07-30-2009, 12:58 PM   #25
thrasher
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My brother-in-law came through with a photoshop of the grille painted WRB. So what's the concensus - should I paint it WRB or flat black??



J
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