S4 grill mesh in standard lower grill ("Eddie man mod") - pictures inside

[maccalo]

I recently bought an S4 upper grill from a salvage car, and decided I wanted to have matching mesh in my lower grill.

Since I got the lower S4 grill, with broken tabs for $12 (!!), I decided it was worth modifying:

S4 grill vs. standard grill


Separated from their frames (the S4 grill is actually wider, even though the picture may fool you)


Cut away these tabs to make it sit flush against the original grill (so you know where to cut)


Use zip ties and fasten the original grill to the front side of the S4 grill. Make sure to leave approx 3 mm step between the top of the grilles, to get the correct dimensions when cutting away the bottom part


Use the blade from a big hacksaw, and use the curve of the original grill as a guide when cutting the bottom part. Repeat on the sides, but here you need to make a straight cut, not angled like the bottom part.


3 of the "hooks" matches between the grilles, but some modification is needed


Cut away these tabs


Test fitting


I attached the grill mesh to the frame by drilling 4mm holes and using machine screws (6 in total)


Finished product!


Now I need to improvise on how to attach it back to the car.

[customa4]

Wow. Looks really good, nice work.

[maccalo]

Updated with a new photo of the final look.

[CyberPMG]

Clever retro fit of the S4 grill.

[maccalo]

Uploaded photos again for future reference

[19jdog]

Looks Great! I don't think that will work for us usp guys.