at first i wasnt sure if it was going to work out, but i went with it, and it turned out great. So if your up to the task then listen up.
first you'll need a large sheet of ''expanded metal mesh'' you can get this from home depot but they only sell 2' by 2' sheets, so you might have to go to a material distributor of some kind. i got lucky and found an old patio table that was made of it.
step 1. pull out the grill, set it on a work bench and place the sheet over the insert. then mark out the outline with a sharpie, make it bigger than you need cuz you'll have to do triming later. i found that a good pair of tin snips works best for cutting and triming. then you will have to bend the metal so it matches the curve of the insert as best as possible...
step 2. then you have to take a ''fish saw'' to the plastic and cut out the fins inside the insert.
(its a mini hacksaw) -NOTE, there is a clip on the insert that you need to keep, so it holds the grill in place. so cut out all the fins and leave a ''vertical support'' in the middle.
now do some final triming around the edges and make the mesh actually a bit smaller than the plastic edges, like 1/8'' smaller so you dont scratch your paint when you install it.
now apoxy the crap around the edges, and if there is excess then you can trim it off later. apoxy untill you are satisfied with the strenght of the peice.
let apoxy bond overnight in a warm place.
(i used all purpose drys in 5 mins apoxy)
step 3. trim off the extra apoxy, the peice should fit! if not trim, or sand off around the edges until it does fit. once it fits then prime and paint!
-when doing the main grill, i just apoxyed the rings on with the quattro badge. then i mesured and cut out a hole for the hood realise pin.
now more pics...
its time consuming, and you need to be a hands on person to pull it off.
good luck
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Originally Posted by rocky.ca
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