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Old 08-13-2007, 11:56 PM   #1
Handsdown
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Default incomplete bugeye grill DIY(progress thread)

so i did this today:


i'm hoping to make it look like the prodrive grill that relocates the badge to the bottom to make it look more like the wrc car.

next step is to clean up everything (make the inside of the main grill smooth) and cut out the oval cutout thing. i have a pink i badge i'll be putting on there too.

after that i'll just epoxy the oval badge mount to the bottom and fill out the back with black chicken wire or whatever.

post up with tips or if you want to make fun of it, or discuss.

i have some plastics primer so i'll probably hit it with that once it's done then get some textured black hammer paint. or chrome. or color changing paint. or something else ridiculous. i'm not sure. probably just black.
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Old 08-14-2007, 12:40 AM   #2
clbd39
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can't wait to see the finished, hope it turns out ok! lol
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Old 08-14-2007, 12:47 AM   #3
robbieshonda
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yo brudda I have some goo dmesh from when i did my pillarless mod if you want some..already cur for the shape of the grill..so if you get ahold of me tomorrow maybe we can meet up and I'll give it to you.
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Old 08-14-2007, 12:54 AM   #4
HinshawWRX
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I remember doing this to My04, thought after cutting "WTF did I do"

looks good now though
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Old 08-14-2007, 08:57 PM   #5
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well... here's the second installment.



as you see, cutting out the thick lattice/honeycomb of the stock grill leaves a bunch of knubs that you have to later sand down... and when you're doing this all with a corded dremel rotary tool, there's just not a lot of room to maneuver and i'm not that handy to begin with.

the other problem is that the clips that hold the grill to the lights are pretty structurally integral and they're right behind the side peices that you'd think would need to come out.

it's too bad, but this isn't a simple hack job. i'm going to either JB weld or bondo over all of the spots i had to sand through... maybe i'll just cover it with some kind of flat adhesive or something.

the other thing that i'm doing is sticking the oval badge holder and badge down on the bottom of the grill to make it look like the wrc car. that's why you see the bottom is cut off of the oval holder. i'll probably epoxy this down sooner or later in the next step.
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Old 08-14-2007, 09:02 PM   #6
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Hmm, I like this idea. I have a spare grill laying around too, so I'll be very interested to see how this turns out.

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Old 08-14-2007, 09:32 PM   #7
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+1 on creativity
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Old 08-14-2007, 11:29 PM   #8
robbieshonda
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hey brother you try using the little router bit? I have a thin right around 3/16th inch router bit that i use for cutting for front mounts ect. but i trimmed my grill quick and easy with it.
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Old 08-14-2007, 11:31 PM   #9
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i used a fiberglass drill bit for a 'bit' of it but basically stuck to the cutting wheel and sanding attachment.
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Old 08-15-2007, 01:29 AM   #10
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well it was going to be very hard to have it stick straight up so after a bunch of sanding and cutting i glued it to the base... it tilts into the car. maybe it will be more aero for the radiator

here's what it looks like now... needs bondo filler and prime/paint and of course, grill mesh behind it.
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Old 08-15-2007, 01:32 AM   #11
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Looking good. Very creative.
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Old 08-15-2007, 01:33 AM   #12
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dang. does not look bad at all. i may have to revert to stock or a prodrive grill also.
put that plasticfusion to work did you?
looks good though.
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Old 08-15-2007, 01:35 AM   #13
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lol..... Im about to donate my oem grill that is laying around to you.
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Old 08-15-2007, 01:35 AM   #14
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haha damn this **** stinks. you bet i did.

stevey- hold your chickens... don't count your horses before they hatch! seriously i don't have any clue how this is going to turn out. plus school starts soon and i just found out i will more than likely start a job before the end of the week.
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Old 08-15-2007, 02:07 AM   #15
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Great job so far man, can't wait to see it all said and done!
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Old 08-15-2007, 02:07 AM   #16
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man you know what, that **** is leet. I have never seen a subie grill done like that (with the badge on the bottom all tilted). Sand that ****, paint that ****, and throw a mesh grill behind that (maybe even slant the mesh and its good to go. I wana see pics of it installed
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Old 08-15-2007, 03:59 AM   #17
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very interested to see how this turns out. keep it up!
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Old 08-15-2007, 07:37 AM   #18
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Looks good. The badge sits more angled than I would like, but maybe it's just the camera angle.
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Old 08-15-2007, 08:43 AM   #19
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thanks for the comments guys.

the grill is tilted back in that picture(resting against the microwave) so it's a little more slanted than it will look on the car, but it's still very angled... i'd say it slopes back at maybe 60 degrees. i don't know how i feel about the angle yet.

I'll probably do a bit more sanding today and then fill it over with something, as there are lots of little holes where the honeycomb used to be.
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Old 08-16-2007, 09:34 AM   #20
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cool stuff man. it should look great when done.
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Old 08-16-2007, 10:23 AM   #21
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loooks good..even w. the tilt
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Old 08-16-2007, 10:27 AM   #22
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you should call it the B-roke ass grill, you are the DIY king
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Old 08-16-2007, 10:32 AM   #23
Handsdown
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Quote:
Originally Posted by bren wrx View Post
you should call it the B-roke ass grill, you are the DIY king
i'm sure this will look better than the liberal replica crap that everyone runs(have one in the closet if anyone wants one)... and more unique than the sti grill that everyone else runs. 150 bucks isn't 'too much' for a grill but it's more than i want to pay.

i'm waiting for the jb weld to dry so i can sand it down. i hope it sands. if not i'll have a lumpy and solid grill

Last edited by Handsdown; 08-16-2007 at 10:40 AM.
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Old 08-16-2007, 10:34 AM   #24
bren wrx
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nothing with a hacksaw and epoxy will look better then anything on the market less the zerosports fisheye grill
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Old 08-16-2007, 11:15 AM   #25
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Quote:
Originally Posted by Handsdown View Post
i'm sure this will look better than the liberal replica crap that everyone runs(have one in the closet if anyone wants one)... and more unique than the sti grill that everyone else runs. 150 bucks isn't 'too much' for a grill but it's more than i want to pay.

i'm waiting for the jb weld to dry so i can sand it down. i hope it sands. if not i'll have a lumpy and solid grill
Have fun sanding JBWeld...I used it for my grill
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