How to mod and mesh your oem grille

[cruisn]

Ive been getting a few request lately and as i picked up an Outback grille for free, thought id do a DIY/walkthrough on meshing the oem grille.

Tools used for this step is any thing to cut out the inner parts roughly, I used a plaster saw (Im an electrician. )

I will be keeping the chrome surround as i like that look, inside will be metallic black with black mesh.

Starting off with a stock Outback grille...



I cut out the entire centre of the grille...





Next up will be removing all the remaining protusions into the grille for a smooth, clean inside section...

[cruisn]

First I marked all around the grille, just enough to remove the vertical bar section. I then cut this out using a Dremel with cutting wheel, then sanded the whole edge smooth.



Any remaining protusions I ground back with the dremel and then finished smooth with sandpaper.





Now left with a nice, smooth, open grille area.





Next is to fill the gaps left from the horizontal bars.

[cruisn]

You have to back the open areas left from the horizontal bars with something solid to provide a good base for the filler. I used a layer of fibreglass for this, cutting it to shape before applying the resin. A small overhang is good as you need to overfill the void to make the new edge.



I then used bodyfiller to fill the void. Make sure its overfilled.





Now its back to a dremel to remove the excess and then sanding to finish off.







Next up is prep and paint.

[cruisn]

I then masked out the grille. I use electrical tape for this as you can run it smoothly around corners, the cover the rest in masking tape.

I sprayed the filled areas with high fill putty and then sanded it back to fill any flaws. I repeated this twice. (forgot to take photos)

Clean up with some turps to remove any dust / residue and undercoat the grille.





Then a very light sand, turps again and apply your color. I used a satin black.







Now ready for the final step..... mesh.

[cruisn]

Bought some mesh from Supercheap. Cut it out to cover the open grille area with about 20mm overhang around all edges. You may have to cut out certain areas as i did to clear supports, mounts, etc.



Lay the mesh in place and fold it around the edges.



Then glues it in place at a few areas ound the grille. Ive found silicon/sikaflex best. Unforunately ran out of black silicon.

[cruisn]

All done, pretty happy with the result.

Whacked a few different badge options in there for a few different looks.











Grille will be listed for sale.

[AndySTi]

I think this should be in the how to/walkthrough section?

[cruisn]

As do I, but I wasnt able to start a new thread in there for some reason?

Mods can move it easily enough.

[cruisn]

Second post added.

[hamish_023]

shotgun this on if you sell looks very interesting, will keep posted

[cruisn]

shotgun this on if you sell looks very interesting, will keep posted

I will sell this when its done Hamish as AFAIK it doesnt fit the GT (havent tried to fit it).

[nytrojen]

*waits patiently for rest of walkthrough to come online*

[Sentinel]

Looking good mate. Maybe I should post my stuff to run in conjunction with yours for a Liberty grille.

[subyroo]

Looking good mate. Maybe I should post my stuff to run in conjunction with yours for a Liberty grille.

Why not, the more options Members have the better and somebody may prefer your method and finish to somebody else's, we are all different you know.

[cruisn]

Looking good mate. Maybe I should post my stuff to run in conjunction with yours for a Liberty grille.

Why not, the more options Members have the better and somebody may prefer your method and finish to somebody else's, we are all different you know.

Quoted for the truth.