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View Full Version : DIY: RS4 Grille to DTM Bumper



fly300kts
05-28-2009, 01:17 PM
Hi Guys,

Because I did not like too much the look of the Non S-Line grille with my DTM bumper, I decided to modify an OEM RS4 grille to fit the DTM. Because some of the fellows Ziner’s asked for a DIY and I don’t mind sharing for the Community, here it its. Of course, you are responsible of what you are doing.[:D]

Time: 4 hours
Tools: Usual ones but Dremel is Mandatory
Difficulty: 5
Look: Priceless

You need these Materials. Don’t take any shortcuts; this is the best stuff that will give you the best results! PM me if you need a links where you can find them. Because I choose the Fusor with really fast cure time (2 mn), I suggest you order more than one mixing nozzle (left on the picture). I used a total of 6 for this project.
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9091Large.jpg

So, here is your challenge
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9077Large.jpg

Using the Dremel, start to cut the bottom piece of the non S-Line grille right below the plate holder. Cut the sides to keep the holes, we will use them later on.
Should look like this:
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9078Large.jpg

Then
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9083Large.jpg

And the 2 holes that you need to keep, above the plastic clip
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9089Large.jpg

Now, on the bottom and each side, you are going to grind down the fins left over until you get this:
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9085Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9090Large.jpg

You are now going to fill the 2 cuts on each side using the Fusor. Put a piece of tape on the back of the trim and use the gun to apply. Hurry, it cures in 2 minutes.
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9092Large.jpg

Then, using Dremel and sand paper, smooth up the profile
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9093Large.jpg

You are done with this one, you can have a beer…..Crap, 10:30 AM, let’s wait a bit for the beer.

You are now going to cut the RS4 grille as such
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9079Large.jpg
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9082Large.jpg

Then, using a box cutter or the Dremel, trim down the remaining tabs like this.
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9081Large.jpg

Leave the sides as shown we will cut them later on
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9087Large.jpg

Now, the little trick:
Superpose the old trim with the new one and use a drill bit to center one from each other. Do that on both sides
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9095Large.jpg

You can now, using a hand saw blade, cut both piece at the same time and obtain a perfect and identical cut on both piece
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9096Large.jpg

Reinstall the non S-Line chrome trim to the RS4 grille
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9097Large.jpg

Now insert the non S-Line piece to the chrome trim and cut the 2 corners that we left over as requested. Then, using the Fusor, secure the 2 pieces together
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9098Large.jpg

From the back of the grille, secure using Fusor, each little square to the bottom of the non Sline trim
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9099Large.jpg

The added piece was not exactly the same color so I sprayed some flat black
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9100Large.jpg

Guess what, you did a great job and have now a RS4 grille that fits a DTM Bumper.[wrench][drive][race]
http://i31.photobucket.com/albums/c395/fly300kts/DTM%20Grille/IMG_9101Large.jpg

PM me if any question
Phil aka Fly300kts

07BlackA4
05-28-2009, 01:21 PM
youre a brave man. great work, as always.

aznpxdd
05-28-2009, 01:24 PM
Wow, nice work.

fly300kts
05-28-2009, 01:27 PM
youre a brave man. great work, as always.

Thank you for the kind words [up]
I'll post pictures installed on the car as soon as:

- DTM carbon lip is delivered [eek]
- Filler plate is delivered [eek]
- Stops raining and the car is washed [:D]

RedS-line
05-28-2009, 01:35 PM
outstanding work! i didnt realize that the top section of the grill was the same and that only the bottom needed to be altered. i assumed that the entire mesh would need to be removed and then transplanted into the nons-line grill since they both have different filler plates. looking forward to finished pics.

Bllzll
05-28-2009, 01:42 PM
this has been done many times. but this is BY FAR the best documentation of the process. great contribution! +rep for you

ZEM930
05-28-2009, 01:45 PM
WOW Phil! You do not stop impressing!!! In for pics! :-D

Jetblast
05-28-2009, 02:49 PM
Nice work[up][up]

_norrland_
05-28-2009, 02:56 PM
Really nice, want to do that to my grill to :D

JMG
05-28-2009, 03:03 PM
GREAT WRITEUP!!!! I really wish they sold a non-sline with RS4 mesh, because I don't have the time, skill, or balls to do what you did. Wanna make me one for some $$?

Good job, post a pic!

+rep for you

djvice
05-28-2009, 03:07 PM
If anyone can do it, Phil can!

Add to FAQ!

Eldritch
05-28-2009, 03:08 PM
Very nice job

jmars
05-28-2009, 03:08 PM
^^^^^^^x2!!!!!!!!!!!!

I would think by now someone would've manufactured one

fly300kts
05-28-2009, 03:55 PM
Well, if anyone is interested, I can definitively do it for you. PM me and we can talk about it.

PS: This grille changes completely the look of the car and she is now really mean.

rnp614
05-28-2009, 04:15 PM
Pics of it installed?

fly300kts
05-28-2009, 04:24 PM
A quick one for you, it's pouring rain in Florida[headbang]

http://i31.photobucket.com/albums/c395/fly300kts/IMG_9103Large.jpg

ZEM930
05-28-2009, 04:38 PM
Well, if anyone is interested, I can definitively do it for you. PM me and we can talk about it.

PS: This grille changes completely the look of the car and she is now really mean.

V3 LEDs!?! Does it really get any better!?! I'm waiting patiently! We need teaser pics! Btw this grill mod is making me rethink my decision to repaint my grill!!

evilgabbie
05-28-2009, 04:40 PM
Great great work !!! Looks perfect with the dtm bumper

fly300kts
05-28-2009, 04:50 PM
V3 LEDs!?! Does it really get any better!?! I'm waiting patiently! We need teaser pics! Btw this grill mod is making me rethink my decision to repaint my grill!!

Should know within a week:

The good
- Improved intergration. It will look like there is no strip added
- Less LED (TBD)
- LED 8x brighter
- I keep a surprise [evilsmile]

The bad
- More expensive (when you will see the final product, you will understand why)

However, If a Customer who has purchased my V2 design will get a discount on the V3

Don't ask for pics: I don't have any
Don't ask for price: I don't know yet

Phil

casuso
05-28-2009, 04:59 PM
This is a PERFECT job!!!

I would love you to do that for my car, but paying the air fare for you all the way to Mexico is to much!! [>_<]

fly300kts
05-28-2009, 07:04 PM
This is a PERFECT job!!!

I would love you to do that for my car, but paying the air fare for you all the way to Mexico is to much!! [>_<]

I'll let you know if I am in the Mexico area during one of my flight [up]

ZEM930
05-28-2009, 08:17 PM
Awesome Phil!!! Very excited! Brighter would mean more like OEM. I assume? Either way I'm pumped!

20A4Audi1.8t01
05-28-2009, 11:43 PM
Looks great man! I think some S4 mirror caps would tie the car off very nicely [up]

4RingRook.
05-28-2009, 11:50 PM
Grille looks incredible Phil.

Props for making a DIY on this! +rep!

artinmoTTion
05-29-2009, 12:35 AM
You rule, and that looks professional, as always. I cringe to think this took time away from figuring out the LED Avant tails, however! [:|]

What I'd like to figure out though for my DTM bumper is how to change from the chrome finish of the surround to the brushed finish of the RS4 grille. The honeycomb is kind of "meh" for me, but I love the satin/brushed look of the RS4 grille, and it would then match my S4 look mirrors . . .

Obvis07
05-29-2009, 12:47 AM
WOOO PHIL!!!!!!!

FryXS9
05-29-2009, 05:31 AM
Looks awesome! [race]

I bought the CF lip yesterday here @VW for 510$ [headbang]
But it´s really it´s worth! The Pre-Owner of my car has painted it [=(]

ZEM930
05-29-2009, 06:44 AM
You rule, and that looks professional, as always. I cringe to think this took time away from figuring out the LED Avant tails, however! [:|]

What I'd like to figure out though for my DTM bumper is how to change from the chrome finish of the surround to the brushed finish of the RS4 grille. The honeycomb is kind of "meh" for me, but I love the satin/brushed look of the RS4 grille, and it would then match my S4 look mirrors . . .


Get it painted aluminum look that's what I did and it looks great!!!

_norrland_
05-29-2009, 09:50 AM
Thats really sick, build one for me ;)

fly300kts
05-29-2009, 12:30 PM
By the way, if the Moderators are willing to add this to the FAQ's, I have no problem with that.[up]

LAS
05-29-2009, 01:38 PM
awesome write-up!!!

definitely useful if you don't have s-line.

lowestA4
05-29-2009, 02:37 PM
I love your "hands-on" mentality. Hard to cut brandnew parts but definitely worth the results.

Hands down..

SDA4
05-29-2009, 03:26 PM
very impressive! It looks flawless.

fly300kts
05-29-2009, 03:44 PM
I love your "hands-on" mentality. Hard to cut brandnew parts but definitely worth the results.

Hands down..

Thank you.
Don't make me wrong, it has not been always the case as far as success and sometimes I had to buy parts twice[:D] but with time, on all the different projects, you build experience [wrench]

jstahmann
07-13-2009, 07:34 PM
Looks great!

Just to make sure Grassmonkey gets credit for doing this mod and the DIY writeup first over 2 years ago...

Credit where credit is due (http://www.audizine.com/forum/showthread.php?t=120203&highlight=dtm+rs4)

fly300kts
07-13-2009, 08:56 PM
^^ Was not a Member of this Forum 2 years ago [:D]
And if it has been done before, great [up] I don't claim any pride out of this, just try to help the Community [;)]

mfproAudi
07-14-2009, 10:05 AM
haha nice man. expensive part to be cutting, but very nice job.

assassinroon
07-14-2009, 10:38 AM
ur the man fly i need to take a road trip to florida lol

Hyphy
07-15-2009, 04:13 PM
Looks great!

Just to make sure Grassmonkey gets credit for doing this mod and the DIY writeup first over 2 years ago...

Credit where credit is due (http://www.audizine.com/forum/showthread.php?t=120203&highlight=dtm+rs4)

That wasn't necessary, he wasn't doing this for 'credit' or 'brownie points', sorry it's such a pet peeve to see someone try to ruin someones party..[>_>]

"give credit to the real dude who did it first"

lmao..

inertia
07-15-2009, 08:25 PM
Sweet DIY! You did an awesome job! [wrench] [up]

slick.rick888
07-15-2009, 10:13 PM
ur the man fly i need to take a road trip to florida lol

pick me up on the way! [:p]

looks great man, i should be getting LED's from you soon, once im home from virginia :)

AudiTFSI3o3
07-15-2009, 10:30 PM
Your a master for custom mods. I praise thee.

fly300kts
07-16-2009, 06:07 AM
pick me up on the way! [:p]

looks great man, i should be getting LED's from you soon, once im home from virginia :)

A fellow Ziner is driving tonight from North Carolina for surgery Saturday:
Front and Rear LED Headlights + HID kit
Going to be a busy WE [:D]

SDA4
08-17-2009, 04:00 PM
I'm pretty sure I'm going to do this.

fly300kts
08-17-2009, 08:53 PM
^^ Feel free to call if any question

Phil

iconoclast
08-18-2009, 07:59 PM
excellent work for a diy... well done~!

SinWolf
08-19-2009, 07:22 AM
GREAT DIY !!!! [up][up]

Did you perhaps do a DIY on the foglights you installed on your DTM bumper ?? What fogs did you use ?? Doesn't the heat generated from the fogs damage the plastic grille's ??

Thanks

fly300kts
08-19-2009, 07:47 AM
GREAT DIY !!!! [up][up]

Did you perhaps do a DIY on the foglights you installed on your DTM bumper ?? What fogs did you use ?? Doesn't the heat generated from the fogs damage the plastic grille's ??

Thanks

No I did not for a simple reason:
I machined the brackets so a simple DIY would not have helped.
I have HID in the fogs and no issues with the grilles

Phil

SinWolf
08-19-2009, 10:58 PM
No I did not for a simple reason:
I machined the brackets so a simple DIY would not have helped.
I have HID in the fogs and no issues with the grilles

Phil

Ok... cool [;)]

Did you use your original OEM fog lights with an HID kit, or did you use a complete different fog light housing ?

Thanks

P.S. Sorry for the "off topic" questions...

fly300kts
08-20-2009, 06:09 AM
^^ I used the OEM fog lights and dropped a HID kit inside (H11 - 5000K)

Phil

jriddle11
10-20-2009, 01:23 PM
This needs added to the DIY section.[up]

fly300kts
10-20-2009, 08:52 PM
^^x2
Already asked the Moderators but no answer [:(]

Phil

3IRA8I
02-26-2010, 02:46 AM
Great work :)
I really like your DIY, but I dont dare to do it by my self :$
Is there anyone who is willing to do it against a payment?

Regards

fly300kts
02-26-2010, 05:39 AM
PM sent

Phil

NTLWNF
05-02-2010, 07:06 PM
Fantastic

Echo3One
05-02-2010, 09:23 PM
Great work :)
I really like your DIY, but I dont dare to do it by my self :$
Is there anyone who is willing to do it against a payment?

Regards

X2

OJwerks
05-02-2010, 09:42 PM
funny, i was toying with the idea of buying an RS4 grill and do exactly the same once the DTM bumpers come in... excellent work!

psiaddict85
05-02-2010, 11:37 PM
Just did the the same thing today!

arce909
05-03-2010, 01:01 AM
^^^any pics... Was it difficult?

xULx
08-17-2010, 02:57 PM
Bumpity bump...I know its taken me while, but RS4 grill and fog grills mod starts today, probably ends tomorrow ;)

fly300kts
08-17-2010, 03:20 PM
Bumpity bump...I know its taken me while, but RS4 grill and fog grills mod starts today, probably ends tomorrow ;)

Doubt it that you will have both done in one day. Take your time but do it right

Phil

xULx
08-17-2010, 05:21 PM
Yeah phil doing the main grill today, and some of the prep on the fogs. Tomorrow I will finish the fogs up.

beantown
08-17-2010, 06:09 PM
Jesse - do my fogs too while you're at it bro lol

But seriously, definitely post up pix when they're done!

xULx
08-18-2010, 10:10 PM
Finished Yall, putting the bumper back on now, pics tomorrow. oh yeah THANKS PHIL!!! Are you adopting? lol.

fly300kts
08-19-2010, 05:41 AM
Finished Yall, putting the bumper back on now, pics tomorrow. oh yeah THANKS PHIL!!! Are you adopting? lol.

Your welcome, I am glad my DIY helped. As far as adopting, let me think about it Jesse[:D]

Phil

Sal_B7
08-19-2010, 07:11 AM
shit was a PITA! Looks pretty sweet though!

fly300kts
08-19-2010, 07:28 AM
shit was a PITA! Looks pretty sweet though!

Hey, I never said it was easy....[;)]

Phil

xULx
08-19-2010, 10:36 AM
shit was a PITA! Looks pretty sweet though!

This guy right here, lol. Sal is like my personal turbo angel.

xULx
08-19-2010, 10:59 AM
Im just going to leave this here and stop thread jackin Phil. Although this is the result of Phil's thread.....hmmmm. New thread up tonight, cause the night pics will be insane,lol

http://i204.photobucket.com/albums/bb14/urban_legends27/Black%20Audi/Hithere.jpg

fly300kts
08-19-2010, 12:00 PM
Carbon lip and filler plate and you are good to go

phil

beantown
08-20-2010, 08:59 AM
Im just going to leave this here and stop thread jackin Phil. Although this is the result of Phil's thread.....hmmmm. New thread up tonight, cause the night pics will be insane,lol

Nice man! Looks great, but you still need that front splitter. How long did the fogs take to complete?

xULx
08-20-2010, 10:36 AM
Nice man! Looks great, but you still need that front splitter. How long did the fogs take to complete?

Thanks. The fogs took roughly 10 hours from start to finish. Its all a process man.