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Old 11-09-2007, 08:56 AM   #1
Sausage
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I haz teh bed gramers

Smile DIY SSAC FMIC Shroud & grill

Yup... another one of these writeups... ever since I learned about the magic of fiberglass I can't stop.

Anyways,

Here's what we're making:



This one is easy, all you need is:

1 can of truck bed liner
Some fiberglass matte OR thicker flat plastic sheet
Resin
2 90 degree brackets
Masonry mesh from home depot
couple of bolts.
2" strait bracket

Prep: I noticed that a lot of people have some rough dremel spots after cutting their front bumper. To smooth those out, get a sanding block and some 60 grit paper. Hold the block perpendicular to the cut edge and go to town in long smooth arcs for about a half hour or as long as it takes. After you're done, you should have a smooth lower cut. (not necessary but looks nice)

1.) Get some cardboard and make some mock side plates. Meaning, just do some trial and error with the cardboard until you have the sides lines up nicely. Both sides aren't going to be identical unless you bolted the fmic in place with laser guided precision.

2.) If you're using matte and resin, put down a piece of aluminum foil on a flat surface and make a flat large square that you can cut the side pieces from. use 2 layers of matte to make it nice and hard.

3.) Cut the side flaps from either plastic4.) or your fiberglass piece.

4.) cut a large chunk of mesh from the masonry mesh. It should fit inside the hole in the bumper but should be taller then the hose by about 6"

5.) Then, make a 90 degree bend in the netting about 1.5" off the bottom kind like this:


You will use this bend to bolt it to the bumper that way it sits flush with the cuts in the bumper.

6.) Take the 2" strait bracket and bent 2 90 degree bends it it. This will hold the mesh to the top of the bumper, Like



7.) Next, bolt on the side pieces to the flaps in the bumper using the 90 degree brackets.



8.) Once everything is set and looks good, you will flip the bumper in it's face and apply small amount of resin to the places where the mesh overlaps the back of the sides. Like in the pic above. Do a little bit at at time because it will run. If it runs off the edge, use a tooth pick to get it off. Try to clean it as best as you can while it's still semi soft. Before it gets really hard, it gets jelly like and crubles off, this would be the best time to get the last little pieces.

9. Once everything is set, take it off and spray it down generously with truck bed liner. Make sure you cover all the metal.

10. Bolt it up and seal off any small crack from the back with what ever black goo you want. I used window ribbon, the stuff that seals your windows or the front headlights.

And that's it, easy as pie
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Old 11-09-2007, 09:52 AM   #2
Rene2.5RS
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Nice write up. Looks great.

-Rene
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Old 11-09-2007, 11:19 AM   #3
chewbakarox
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Looking good. DIY FTW.
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Old 11-09-2007, 12:44 PM   #4
vtecTHIS
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i thought about doing something simialr with metal. looks good. i kind of like the way mine looks though. not so much open area on the 04 w. the ssac
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Old 11-09-2007, 02:04 PM   #5
chris-man
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looks good
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Old 11-20-2007, 10:12 AM   #6
Rene2.5RS
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Did some thing similar. Thanks for the write up.













-Rene
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Old 11-20-2007, 10:46 PM   #7
demartinoink
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looks good!
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Old 11-21-2007, 10:01 AM   #8
CTKAG
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The only issue I've had is that screening will eventually tarnish or rust & look like crap. I'd shoot some epoxy enamel (I like the Russel's Chassis Epoxy) on it before mounting.

-Keith-
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Old 11-21-2007, 10:08 AM   #9
Rene2.5RS
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Quote:
Originally Posted by CTKAG View Post
The only issue I've had is that screening will eventually tarnish or rust & look like crap. I'd shoot some epoxy enamel (I like the Russel's Chassis Epoxy) on it before mounting.

-Keith-
I coated mine in rubberized under coating for that reason and to better withstand getting hit from road debris .

I believe the OP stated to used the undercoating in his write up.

-Rene
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Old 11-21-2007, 11:10 AM   #10
Sausage
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I haz teh bed gramers

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Yup, rubberized undercoating FTW.

BTW, nice job on the grille!
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Old 02-03-2008, 07:27 PM   #11
awdturbo04
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Old 02-03-2008, 10:44 PM   #12
Julianh06
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looks good
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Old 02-04-2008, 12:27 AM   #13
Rene2.5RS
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Came out looking good. Nice work.

-Rene
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Old 03-17-2008, 07:13 AM   #14
pawlooo
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bump for a great idea
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Old 06-27-2009, 05:58 PM   #15
Ashr
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Is their a write up to removing the front nose to get to the grill? I need to replace mine but have no idea how to get it started!!
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Old 06-27-2009, 07:33 PM   #16
cpunlamd
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Quote:
Originally Posted by awdturbo04 View Post
IMO you should move the shrouds a little farther to the sides. Show a little more end tank. Right now it looks like an a/c condensor.
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Old 04-13-2012, 04:11 PM   #17
Rally Snow
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I'm working on this right now on my bug eye thanks for the ideas!
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