Stoggy's DIY Grill for Legacy BE

[stoggy]

I made this grill in a rather hurry on the weekend. It turned out alright for the 4 hours it took and $10 it cost me. I wanted to buy the new 03-04 body style grill but couldn't justify the price not including the emblem. Mine was in rather rough shape so I said what the hey and threw some time into it...turned out not half bad. I want to put the Subaru emblem in the middle, what do you guys think...sorry for the bad picture quality.

https://sl-i.net/FORUM/images/imported/2011/07/grill-1.jpg

[Matty2Hotty]

Well this really isn't explained or step by step pictures of a DIY as I was thinking when I read the Title... Looks better than stock but you need some Hella Horns now behind the girll.

[chuckthefuk]

^^^^^

What he said..

Add more pics/steps or this is getting moved to the body section

[stoggy]

It already is in the body section....I don't have any good quality pictures so that's why it's not in the DIY section...ill do a writeup of the steps I took tho. But sorry, pics aren't going to happen.

[Huffer]

I edited the thread title for you. The grill looks good BTW, and I'd leave the badge off. I'd spend more time trying to figure out how to improve the front bumper.

[stoggy]

Thanks for the title update...I guess homemade grill would've been a better title. I'll most likely just buy the 03-04 bumper and fogs...saves a lot of time and money versus trying to do anything with this one.

[Greavesy]

I'll be doing something like this with mine soon.

Top work fella! :smt023

[Matty2Hotty]

To spice up the front bumper a little I would get some bumper/trim black paint and spray the left and right sections next to the fog lights/grill deletes would be. I have some shots of my old LGT where I did it on mine. It does make the front pop a little more. Just a idea.

[stoggy]

Yeah sorry, I guess the title is misleading...but I can describe the steps. The pics I took didn't turn out because I was using a DSLR and it was on manual so I didn't focus the images very well, they are all very fuzzy.

Please understand that I spent about 4 hours on this. No it is not perfect, I am usually a perfectionist but this grill has honestly been rock-chipped so badly that it would take way to long to get perfect. I am also very familiar with bodywork and the process, waiting times, etc. This is a big project for someone who has never done anything like this before. Expect to spend 8+ hours to get it absolutely perfect. Keep in mind I also have all these tools and most supplies (except paint) in my garage already. This will cost a lot more if you decide to buy everything here. You would be better off buying a JDM grill for that price. Anyways...

The steps I did are as follows:

Tools/Parts List:

1. Gutter Guard from Home Depot/Rona (in Canada), 2 pieces
2. Tin snips or sharp industrial scissors
3. Bondo with cream hardener
4. Glazing putty (optional, makes for a smoother finish, less sanding)
5. Spreaders (or plastic razor blades)
6. 5-10 Very small zip ties, about 1/16" in width, color won't matter as they will get painted in the end
7. Super glue or the like
8. Dremel with cutting disc or cutting tool of your preference
9. Various sand paper grits 80-220, mostly 120 grit and 220 grit.
10. Paint and primer of your choice. I used regular automotive primer and spray paint. 1 can of each should be lots.
11. Drill with 1/16" bit.
12. Wax and grease remover or your favourite surface prep chemical.
13. General cloths and rags, etc.

NOTE: Before you begin you may or may not need to modify your hood latch mechanism for this new grill to clear! I've read some people have issues and some don't but here is the reason why: The centre section of the grill is hollow, allowing for your hood release lever to hide up inside it when you close the hood. When you remove the centre section and make it flat you now have nowhere for your hood latch to go. Check this out before you proceed because it is a bit of a pain in the ass to modify to make it work properly and look good in the end. I did have to modify mine. You have been warned.

On to the good stuff:

1. Get old grill out of car, there are 9 bolts in all: 4 along the top, 2 on the sides and 3 for the centre support (does not get installed back on the car).

2. If your grill is chrome then you need to sand the chrome to remove the shiny-ness of it. I got lucky because mine was in horrible shape so most of the chrome peeled off--whatever was left I used a utility knife with a fresh blade. If your chrome is even the slightest bit chipped or peeled you will need to strip it all off or it will show through the final paint. Sand grill frame (don't worry about the middle part) to 'rough up' the surface so paint/bondo will stick.

3. Cut out the middle 'wings' of the grill, making sure to get as close to the edges as possible but without causing damage or nicks to it. Sand or file smooth with the rest of the grill frame.

4. Cut some mesh just slightly bigger than the parts of the wings that you cut out. Bottom and sides only.

5. Glue the mesh to the grill frame on the underside. This will provide a backing for the bondo to stick to. Let dry.

6. Mix a batch of bondo big enough to fill both the bottom hole and the sides making sure to overlap, ie: don't just fill the hole, fill the hole AND around it by about 50%. Let dry.

7. Sand away excess bondo with 120 grit. Further sand with 220 to feather the edges so you get a smooth transition. May need more than one application depending on skill level and how bad of shape your grill is in. I needed 3 applications to get a nice look.

8. This step is optional, but it makes for a smoother finish I find when you go to paint. Mix a batch of glazing putty. Spread thinly over the areas you have applied bondo, again making sure to overlap by a bit. Let dry. Sand with 220 only! This putty is really soft and if you use anything less you will put unnecessary scratches in it. Repeat steps 6 and 7 (and 8 if you want) until you are satisfied with the look.

9. Cut and form your mesh to fit the grill using the snips--you can bend the mesh by hand. Take care during this part as this will ultimately determine the final look of the grill. I spent about 30 minutes on this. You will need to test fit and re-test fit multiple times to get it right, trust me. Be careful too as the mesh is sharp when you cut it.

10. Once happy with the fit of the mesh, mount your mesh and attach using zip ties. I drilled all my holes for the zip ties as close as I could to the edges on the top and sides of the grill frame. I used 6 zip ties--1 on each top side and 4 along the top. There are no holes on the bottom flat part as you would see any holes you drilled there and take away from the final product.

11. Now that you have your grill made it's time to paint. Make sure to prep the surface of frame and mesh by blowing any loose dust or bits that may be left from sanding. Again, more time here will determine the final outcome of the product. Prep is everything when it comes to paint!

12. Prime your piece. It took me about 2-3 coats to get decent coverage. At this point you will see any imperfections. If your a perfectionist then you can fill/sand your heart away until it's mint. If not, give a light sand (and I mean light sand) with 220 grit. Remove all dust and use surface prep chemical again.

13. Apply your topcoat of choice. Several, light even coats here, to avoid runs in the paint. Follow the directions for flash time on the can of paint you are using. You can choose to light sand between paint coats if you like, just make sure the paint is dry in between coats.

14. Once done, fit your piece one last time and secure with original hardware, of course leaving out the centre metal support bracket.

[mycargoesvroom]

Nice write up! Grill looks good!

[stoggy]

To spice up the front bumper a little I would get some bumper/trim black paint and spray the left and right sections next to the fog lights/grill deletes would be. I have some shots of my old LGT where I did it on mine. It does make the front pop a little more. Just a idea.

As per your request! No, actually it does look soooo much better than stock. Thanks for this great idea, I never would have thought to do it. I also painted the grill to match!

https://sl-i.net/FORUM/images/imported/2011/08/exterior_front_bumper_5-1.jpg

[Matty2Hotty]

Good!!!!! Yes it looks sooo much better! Hope your happy with it cause it makes your front end look so much cleaner! Add a 06-07 STI V-Limited replica eBay front lip if you want to for $80.

[Greavesy]

does look alot better!

[stoggy]

Yes it is cleaner! Now there isn't so much going on and it's not so busy. Thanks again. In terms of a lip I think I'm gonna hold off, only because it snows several feet here and I'm not crazy about the idea of taking it off for the winter.

I painted the fogs too so they blend in. The reflectors in them were in rough shape so I figured why not try it. It looks good with 8K HID's at night...more of a 'for the look' thing than anything.

Cheers.