How to mod and mesh your oem grille

[cruisn]

Third post updated.

[TH-37-OY]

Ive done something very similar to yours but instead of body filler and fiberglass, I plastic welded the gaps with abs plastic then used body filler to cover the imperfections.

Had it all done a sprayed and ready to fit, forgot to shorten my latch and when I shut my bonnet... Grill slammed on the latch n I ended up cracking my weeks work.

back to the old drawing board for me, and another few cans of paint...

[cruisn]

Next step added.

[cruisn]

All finished.

Pics updated in initial posts. Grille will be up for sale.

[hamish_023]

hmmmm wonder if till fit the 3rb bumper? shotgun if so

[cruisn]

Its an outback grille, so taller profile than the GT, but pretty sure the same as pre facelift RB? i will have to do some research into that.

[hamish_023]

yeh looks kinda similar to mine. how much $$$

[MH3.0R]

Ok guys,

You have inspired me enough by making it look simple. I tackled this mod today and should finish off tomorrow. Pictures not needed as you have great detail in this thread. I may post some of the mounting details as I may do it a little bit different. I am considering mounting the mesh independently of the old grille and using the modified grille as a cover and hold for the mesh. See how I progress tomorrow.

Kind Regards,

Mark.

[MH3.0R]

Hey Cruisn,

I see that you did a really good job on filling the gaps in the grille. A couple of us want to do the same, but have no experience with Fibreglass and Body Filler. Are you able to post up a list of materials/tools/sequence for us (so we know what to buy before we start at least). From reading your set of instructions (which I have several times now) there are a few gaps in my knowledge in order to start confidently. For example, is this a one day job, a one weekend job, or spread over a couple of days. I am assuming we should not do some of this stuff when the humidity is high (like raining)?
My shopping list would look like this:
1. Fibreglass Kit (incl. resin, mat and catalyst). Did you use the resin and catalyst to set the fibreglass mat?
2. Spray Body Filler (it looks white in your photos)
3. Body Filler (looks pinkish red in your photos)
4. Some protective stuff (mouth and nose, eyes, hands).
I already have enough spray paint left over from the 1st finish. A simple plastic primer and Matt Black from Autobarn.
Any help appreciated. If there are more photos, even better. And if you want to join in to guide our enthusiasm, even better still!
Kind Regards,
Mark.

[castek]

hey mark,

you're shopping list is correct mate.

I didnt do the fibreglass, i just did the body filler and it worked fine. To give it a backing i just used some cardboard behind the void.

Buy a can of spray putty to help fill the little pits. But try not to rely on this method.
It takes patience to get it right. I bogged mine, rubbed back with some 400. then re bogged, re sand, and re bogged. Takes a while, but you get a really nice smooth finish.

in terms of mixing body filler (and the glass if you use it) is just as simple as following whats on their packet. Dont add too much hardner to the filler if you're not good with working it quickly, or it will go off too soon and you'll be stuck with filler you cant use.

Also, allow a weekend to complete it. It took me saturday and sunday, but i was doing a few others things at the same time which increased the time.
I would say preparing it, it doesnt matter on weather, actually great for a rainy day. however, for painting, i always like low humidity, around 20degree outside temps, and a bit of breeze.

i have a mini oven set up in my garage to bake the paint. Consists of a massive flood light with halogen globe, and some old pc fans for air flow

hope this helps, and look forward to seeing it on the next cruise

[MH3.0R]

John,

Thanks for the tips. Photos? Nah, just niggling.

I think I can feel some workshopping developing this weekend!

For the Body Filler backing, I was thinking of a firm but felxible clear palstic sheet, to cut and superglue in place (inside), then add the body filler over the top. Any advice to the contrary?

Mark.

[castek]

Only thing I'd say is not to use super glue. Use silicone, atleast that has flex whereas superglue doesn't.

Pics of progress or finished?

[MH3.0R]

Good point about the silicone instead of the super glue.

Both sets of photos if you can be bothered. We are all into details on this forum!

[castek]

I'll try and dig them up. Should be on the pc

[cruisn]

You need something substantial and permanent to back the area being filled. Body filler alone will crack after a short period of time with no support behind it to stop flex. Thats why the fibreglass is used. I just bought another oem mesh grille with a damaged (missing) front side section. I remanufactured and shaped the side and you cant pick it.