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Old 08-26-2005, 06:05 PM   #1
sha_zapple
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1998 Legacy L

Default Chop chop

I wanted to do something to my grill, so I started cutting it in the shape of a JDM one.

I used a long blade (shown at the top right). Using something like areciprocating saw would have made it faster and easier.


Some filing and foila! at first I needed a heavy duty file, and eventually got down to a normal one. The plastic is almost too hard to sand.


I took a piece of tape and wrapped it around the openings, then I used a putty knife to fill in the holes with epoxy/fiberglass. Some of them turned out great, but some had a few dips and bumps which I had to sand and fill. I should have used more epoxy to fill some of the larger dips but i didnt have any around while away from home. Instead I just used some spot putty, which worked out fine (so far!)


I also stuck in some aluminum rods, which help strengthen it. I put them in while the epoxy/fiberglass was drying so theyre not going anywhere!

I still have to sand it down some more, then paint it a few times. Ill be painting it black (white would just look weird)
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Old 08-26-2005, 06:11 PM   #2
Dan Cech
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White

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Nice work!

You'll have to post more photos once it's painted and installed.
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Old 08-26-2005, 06:24 PM   #3
flanders
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At first I couldn't believe you painted it green LOL.
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Old 08-26-2005, 06:42 PM   #4
fibuz
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BE-> GD->GR->SG->BL
WAawd.org

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nice toe!
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Old 08-26-2005, 07:04 PM   #5
Aken
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'02 F4i / '07 ZX-10R

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Quote:
Originally Posted by fibuz
nice toe!
Bah. Beat me to it.

I intend on picking up an L grill and doing something similar. I'm a fan of the nothing-in-the-grill look, so I'll be chopping everything out and putting in some mesh. Probably an STi emblem, too, just for poopies and giggles.
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Old 08-26-2005, 07:22 PM   #6
sha_zapple
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Quote:
Originally Posted by Aken
Bah. Beat me to it.

I intend on picking up an L grill and doing something similar. I'm a fan of the nothing-in-the-grill look, so I'll be chopping everything out and putting in some mesh. Probably an STi emblem, too, just for poopies and giggles.
I considered that as well, but I figured if I dont like this, I still have that as an option.

I rather like the chrome around the grill, so thats why i covered it with green tape. It separates the grill from the rest of the car.
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Old 08-26-2005, 07:23 PM   #7
Aken
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Ah. Yeah I'm a little backwards - I hate all the chrome I'm jealous of WRX owners who have the ability to delete their grill easily. I took mine out and it was just foogly!
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Old 08-26-2005, 11:01 PM   #8
iamrazor
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I also hate that chrome. just seems so out of place on the car. nothing else is chrome except the badges. I'd love to hack up my grille when I have time
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Old 08-28-2005, 11:41 PM   #9
sha_zapple
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All done. Its not as perfect as I would like it to be. If I were to do it all over again id sand down the plastic more, apply a second coat of fiberglass, then use the putty. Then I would use primer to find all the smaller dips. Also, Id take more time painting it.

Of course, yo dont really notice these flaws unless you look at a certain angle. Ill have to get a shot of it on the car later

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Old 08-29-2005, 12:02 AM   #10
EJLsubie
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Mystic Blue

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Originally Posted by Aken
Bah. Beat me to it.

I intend on picking up an L grill and doing something similar. I'm a fan of the nothing-in-the-grill look, so I'll be chopping everything out and putting in some mesh. Probably an STi emblem, too, just for poopies and giggles.


I did something similar to my stock grille for my legacy




I used some left over mesh from a friend wrapped around the opening and glued half inch thick pvc lip on the bottom where I used screws to hold the mesh in place, (2nd picture)
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Old 08-29-2005, 02:19 AM   #11
Diabolical1 CC
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Quote:
Originally Posted by fibuz
nice toe!

Ah I was going to say that.

So why doesn't your Anniversary Legacy have the 4 front headlights?
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Old 08-29-2005, 05:41 AM   #12
fibuz
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Quote:
Originally Posted by EJLsubie
blitzen!

dunno about the i(imprezza) badge though, seems kinda not right

nice none-the-less.

fibuz
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Old 08-29-2005, 06:28 AM   #13
EJLsubie
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Mystic Blue

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Thanks, only reason why I put it was it was listed as an option from the perfomance site of subaru, was looking into the Titanium STI emblem, but ,dunno if it will fit the grille properly, I've seen some Pink sti emblems where it only fits center of the emblem with a .25" gap. I figure with the Blue I it's a reminder where the legacy get's it's roots from.
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Old 08-29-2005, 10:57 AM   #14
MitchGT
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EJLsubie- that is a sweet looking grille man!
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Old 09-05-2011, 10:54 PM   #15
Patrick Olsen
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QuickSilver Metallic

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Bringing this one back from the dead. There are a variety of threads about doing some sort of DIY grille mod, but not many of them still have the pictures left, so I chose to bump this one.

Anyway, I've been wanting to do the empty grille for a while (cut out everything and just put mesh behind the grille). Every time I went to the U-pull-it yards I had my eye out for a grille, but obviously everyone else did, too, because I never could find one. A couple months ago, though, I finally managed to find an intact grille.

So, I've never done any sort of "body work" like this. I'd love to have some more specifics on the use of epoxy vs fiberglass vs bondo vs "spot putty" vs whatever. From what I've seen reading various threads, it looks like the newer Impreza grilles have a flat section even after you cut out the vertical posts, which would make it pretty easy to fill and smooth. But our BD/BG grilles end up with gaps once you cut the horizontal and vertical bars out, and I don't know what exactly one needs to do to ensure whatever filler is used will be strong enough to maintain its shape.

Anyway care to school me?

Thanks,
Pat Olsen
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Old 09-05-2011, 11:20 PM   #16
rougeben83
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silver

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You could buy some sheet styrene plastic from a hobby store and jb weld/glue it under the gaps as a backing for whatever filler/bondo you want to fill in the gaps.

Also, there are fillers specifically made for automotive plastics (used to fill in bumper covers), you can get those from an auto body supply store.
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Old 09-07-2011, 07:47 AM   #17
Patrick Olsen
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QuickSilver Metallic

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Thanks for both tips. I suppose the plastic as backing is somewhat obvious, but I hadn't thought of it! I'll have to see what I can find later this week and start playing.
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