DIY: Custom JDM Grill

[shazapple]

Heres my DIY on making your own custom JDM grill. This picture was my inspiration
http://memimage.cardomain.net/member_images/6/web/486000-486999/486027_29_full.jpg

Tools:
- long saw blade
- pliers
- Heavy file, medium file
- light and heavy sandpaper
- tape
- fiberglass bodyfill
- glazing putty
- Primer and Paint
- 2' metal bar (small enough to fit in the grill, long enough to go end to end)


Step 1 - Taping
Make sure to clean all the dirt and bugs off the grill and parts you tape. I taped off the chrome part and the subaru symbol. If you dont like the chrome then I wouldnt bother taping it off (jsut be sure to sand it well!). You can also tape off the Subaru symbol, or just remove it. Its attached by two sided tape, so you can use a hairdryer to heat it up, and then a knife to pry it off.
http://memimage.cardomain.net/member_images/6/web/486000-486999/486027_30_full.jpg

Step 2 - cutting
First you have to remove the U shaped piece of plastic attached to the back of the grill. I took a pair of pliers and broke off the small posts holding it on.

Now use your saw blade (shown in the top right of the picture) to cut off the vertical parts of the grill. Make sure to get pretty close to the horizontal part, but not too close. If you get too close youll put gouges in that will have to be filled in with glazing putty later. Don't be too rough while cutting because removing the vertical parts takes away a lot of support.
http://memimage.cardomain.net/member_images/6/web/486000-486999/486027_31_full.jpg

Step 3 - filing
Use the heavy file to get rid of the lips left from cutting the vertical parts. Don't be shy about filing them down. I didnt file them down enough and it shows a bit in the paint. Use the medium and smaller file to smooth everything out.
http://memimage.cardomain.net/member_images/6/web/486000-486999/486027_32_full.jpg

Step 4 - filling
Use the tip of a file to rough up the inside where the bodyfill will go. This will help it attach itself to the grill. Place tape over the holes in the grill which will make a mold for the bodyfill to sit in and harden. I used some shorthair fiberglass resin which needed to me mixed with a hardening agent.

Don't fill in all the holes at once, it makes your job harder because you have less time to fix mistakes. Also, its harder to move the grill around with gooey fiberglass. Start with the horizontal piece.

Dont fill the holes all the way, because you have to stick a metal rod in the trench. Add a bit more fiberglass after adding the rod. This helps add strength to the grill, and gives the fiberglass something more to stick to. I didnt put a rod on the bottom because there wasnt much room, although it would have helped.

After about 5 minutes (depending how much hardener you put in) you can take off the tape and use a heavy file to cut down some of the fiberglass. You want to do this while its somewhat soft, or else it turns ROCK hard and requires a lot more work. You might have dips or holes, in which case just mix up some more fiberglasas and stick it in, then shave down. This saves you a lot of glazing putty in the end! Repeat this procedure with the top and bottom holes.

Once everything is hard, continue smoothing everything out with a file and sandpaper. Now move onto the glazing putty. As you can see from the picture I use A LOT of putty, try not to do that! Using a knife spread thin coats over each area. Sand down with some fine sandpaper, repeat as necessary until you get something that looks pretty smooth.
http://memimage.cardomain.net/member_images/6/web/486000-486999/486027_33_full.jpg


Step 5 - painting
You can paint it with primer, which will show all the imperfections, at which time you get out the glazing putty and fine sandpaper! Eventually you are either satisfied or fed up, and you can paint it the colour of your choice! I used a black automotive paint and applied several thin coats every 20 minutes (too much too fast will result in drips!) Let this dry for 24 hours or more. Be sure to inspect the grill afterward for missed spots.
http://memimage.cardomain.net/member_images/6/web/486000-486999/486027_34_full.jpg

Hopefully this was useful to everyone! Take your time and good luck!

[Wiscon_Mark]

good stuff. did you also put mesh behind the bar? I thought I saw that on NASIOC....

Very nice writeup too :smt023 :D

[subieyacht]

that looks great, gues i know what im doing this weekend. so did you use like bondo?

[legacysti95]

Hi this is part 2 for a JDM look for your grill. FOR LEGACY owners that have a L LS LSI grill i will post my own diy when a get a chance it is all most done here is a pic very nice job sha_zapple!

http://memimage.cardomain.net/member_im ... 978_31.jpg (http://memimage.cardomain.net/member_images/1/web/2125000-2125999/2125978_31.jpg)

[shazapple]

I just used a lot of glazing putty, but Bondo would be a better choice to fill in the bigger gaps.

[Wiscon_Mark]

hey, Lee, do you have finished pics of it on your car?

[shazapple]

https://sl-i.net/FORUM/viewtopic.php?t=14

http://img376.imageshack.us/img376/664/car29ea.jpg
https://sl-i.net/FORUM/

I think its a pretty close match :-)

[Wiscon_Mark]

that rocks, Lee :D

[Huffer]

Very nice!

[Legacy4Life]

That's probably one of the nices grill mods I've seen!

Good work!

[blackgtbeauty]

man that looks great. i'll probably do mine the same except with maybe the carbon fiber "rabbit" emblem.

[deadlydave]

well done! I did my grill a little different, I only left the center pillar with the suby emblem. I used gutter mesh behind mine, i'll post pics when I have them. The hairdryer/knife removal idea worked well too, thanks man.

[LeggoMyLeggy]

Dave,

Do you have a picture of the work you did?

/Leggo

[deadlydave]

Picture of mine, for you Leggo: Top one is after cutting and sanding the crossmembers out of my 96-99 grille. Bondoed the holes closed. Bottom one is painted gloss black, with the back mesh and my badge painted red from the inside.

EDIT: BE VERY careful when working with the grill in this state, it is very flimsy. I filled the center pillar with bondo to give it strength, after the first time (the test) I closed my hood it had cracked.

http://www.cs.sunyit.edu/~trifard/images/grille/grillexample2.jpg
http://www.cs.sunyit.edu/~trifard/images/grille/grillexample.jpg

[LeggoMyLeggy]

Thanks! That looks good, and I think I will do the same. I might keep the chrome trim on the outside though.

/Leggo

[WinterKnoll]

I'm currently doing this project, except instead I also removed the center Subaru badge. I'm also mounting recessed mesh behind it. I used wayyyy too much Bondo though and it's taking forever to sand down. I'll get some pics up when I'm finished.

[89bk]

WinterKnoll, got a photo of your finished grille? :grin:

[WinterKnoll]

http://img465.imageshack.us/img465/2436/picture001jk7.jpg

[deadlydave]

wow, looks good. That must have taken a while to do.

[WinterKnoll]

Thanks, and haha it did take awhile, I used sooo much bondo.

[Huffer]

- 2' metal bar (small enough to fit in the grill, long enough to go end to end)


Dont fill the holes all the way, because you have to stick a metal rod in the trench. Add a bit more fiberglass after adding the rod. This helps add strength to the grill, and gives the fiberglass something more to stick to. I didnt put a rod on the bottom because there wasnt much room, although it would have helped.


Quick question - would it be better to bondo-fill the rod into the grill before cutting the vertical pieces out? ie. add some strength to the structure, then cut out the undesired parts?

Likewise with the bottom part of the grill?

[deadlydave]

- 2' metal bar (small enough to fit in the grill, long enough to go end to end)


Dont fill the holes all the way, because you have to stick a metal rod in the trench. Add a bit more fiberglass after adding the rod. This helps add strength to the grill, and gives the fiberglass something more to stick to. I didnt put a rod on the bottom because there wasnt much room, although it would have helped.


Quick question - would it be better to bondo-fill the rod into the grill before cutting the vertical pieces out? ie. add some strength to the structure, then cut out the undesired parts?

Likewise with the bottom part of the grill?

I don't know if adding that much bondo is a good idea, especially before cutting out the rest. More than a small amount of it will cause it to crack, and that grille gets flexible which would add to that. Maybe fiberglass or something would be a better filler.

[shazapple]

Definitely fiberglass would work better. Bondo would crack and fall out and just make a huge mess before you're even done sawing.

[Tazmaniandevil]

When I did mine, I stuck some steel rod into the remaining parts with gripfill (http://www.laybond.net/data/laybond/gripfill_ds.pdf).
Lighter than bondo, and still allows a bit of flexibility.

[chipLRX-SLI]

im in the process of doing this to my grill right now and it is turning out sick ill throw up some pics but im gonna do the custom badge too just sand and paint the back of it to match the color of the car

[chipLRX-SLI]

where did you get this glazing putty i liveon the east coast and have looked quite a bit and still have not found this what other alternatives are there instead of this glazing putty

[shazapple]

I just picked mine up at the local automotive place (canadian tire). Im not sure what you have in your area

[SPR]

chip you idiot, u live on the west coast LMAO.

[Reason]

chip you idiot, u live on the west coast LMAO.

lol that's great, I'm glad the educational system is strong on the west coast :lol:

[Wiscon_Mark]

California's grading scale is easier for a reason, folks.

:lol:

[SPR]

California's grading scale is easier for a reason, folks.

:lol:

hey come on now give us some credit, were from oregon, not friggin gay cali lol.

[Legacy]

I just did my cusom grill today. I went to a salvage yard and found me some emblems of off an Impreza. Here is the finished product.http://memimage.cardomain.net/member_images/6/web/2622000-2622999/2622336_8_full.jpghttp://memimage.cardomain.net/member_images/6/web/2622000-2622999/2622336_9_full.jpg

[WinterKnoll]

Wow, very cool, very unique. I'll be interested to see how it looks installed.

[SPR]

WOW. now that looks good. way different that anyone else has done yet, installed pics asap please! im very curious about this.

[Huffer]

I just did my cusom grill today. I went to a salvage yard and found me some emblems of off an Impreza. Here is the finished product.
http://memimage.cardomain.net/member_im ... 8_full.jpg (http://memimage.cardomain.net/member_images/6/web/2622000-2622999/2622336_8_full.jpg)[/img][img]http://memimage.cardomain.net/member_images/6/web/2622000-2622999/2622336_9_full.jpg

That's pretty sweet. Any pics of the back - how did you attach the mesh?

I have some '05 Subaru Legacy GT emblems I could use... hmm...

[Legacy]

I just did my cusom grill today. I went to a salvage yard and found me some emblems of off an Impreza. Here is the finished product.
http://memimage.cardomain.net/member_im ... 8_full.jpg (http://memimage.cardomain.net/member_images/6/web/2622000-2622999/2622336_8_full.jpg)[/img][img]http://memimage.cardomain.net/member_images/6/web/2622000-2622999/2622336_9_full.jpg

That's pretty sweet. Any pics of the back - how did you attach the mesh?

I have some '05 Subaru Legacy GT emblems I could use... hmm...

Just used some wire ties, but I will eventually use the right part to secure the mesh grill.

[RckyMtnLegacy]

Does anyone have pics of the back of the grill with mesh? I cant seem to to get the mesh to fit right. I think my mesh is just cheap too.

[Reason]

I don't have anymore pics of my grill. I drills tiny holes and used thin wires to put mine on, you couldn't even see the wire. Some people used screws, some use some sort of glue. I'm sure someone on here has pics.

[RckyMtnLegacy]

ok thanks. I just think my mesh I bought is so cheap. When I bend it it wants to break. What did you use?

[Reason]

I used something from eBay

[chipLRX-SLI]

that looks sweet i like that yeah with mine i had problems with cracking in my bondo so i redid the cracks and i now need to paint it and install

[Legacy]

Here are some pics of the grill installed.
https://sl-i.net/FORUM/images/imported/2007/10/1722995110_a1d5b3614f-1.jpghttps://sl-i.net/FORUM/images/imported/2007/10/1722994572_163b588e34-1.jpghttps://sl-i.net/FORUM/images/imported/2007/10/1722994022_30189fc064-1.jpg

[Legacy]

Didn't really like how it fit on the Subie, so I put in the other grill. Thinking of selling it.

[IwannaRally]

this makes me want to customize my grill!! i really need one of those subaru emblems mine is just a black circle.

[reckless]

So what is the best way to get the grille off?

[StatGSR]

^ sqeeze upper clips, till they slide through, then pull till u bust out the lower ones... or u could remove the headlights and actually do the lower clips that way... but they are kinda retarded..

[shizznats]

So what is the best way to get the grille off?

I already told you in the other thread. Remove the headlights.

The grille holds in pretty good without the bottom tabs anyway.

Actually there is a way to remove the grill from all the tabs without taking out the headlights. you simply slide out the top four tabs and then pull the top of the grill towards you and pull up at the same time. if you do this gradually the bottom tabs will pop out without any damage (this is from the Haynes manual and ive done it many times without a problem)

[shazapple]

Therea are bolts to the headlights behind the grill, I dont see how removing the headlights is any easier.
pull forward on the grill and then compress the clips on the top from one side to the other, then pull up with a bit of force.

[phat56pat]

good idea!

[LunchBox04V]

Wow that looks amazing guys! I kinda liked how Legacy's turned out. I like the open look. However, I was thinking of having it all color matched including the chrome, to the car. Kinda like this, but with a BK, and in Sandstone. And with the black mesh.
http://memimage.cardomain.com/member_images/10/web/3034000-3034999/3034929_2.jpg
http://www.subiesport.com/images/2008/05/01/img_8620.jpg
http://memimage.cardomain.com/member_images/4/web/2416000-2416999/2416491_1468_full.jpg

Another idea, same open idea, change the chrome around the grill to mat-black, and color match the rest, with black mesh in back?

[Okin DaVanh]

Wow that looks amazing guys! I kinda liked how Legacy's turned out. I like the open look. However, I was thinking of having it all color matched including the chrome, to the car. Kinda like this, but with a BK, and in Sandstone. And with the black mesh.
Another idea, same open idea, change the chrome around the grill to mat-black, and color match the rest, with black mesh in back?

Like this:



https://sl-i.net/FORUM/images/imported/2008/10/l_2244d22cfdf24351966e2a8b0d85c289-1.jpg



I just haven't figured out whether or not I want to paint it yet. Jury's still out.

[slowsti]

very nice writeup...

[Gripp]

Hey shazapple or anyone else who has done this,

Do you have any pictures of the back of the grill? (I.e. where you have put the filler and rod)

That would be so helpful.

Thanks,
-Duncan

[shazapple]

Sorry, I don't have any pictures, but theres really nothing to see anyway. The horizontal piece is hollow, so I crammed some fiberglass/epoxy in it, then the bar, then more fiberglass.
Shave off the excess that sticks out the back and out of the holes leftover from the cutoff vertical pieces and you're good to go

[Gripp]

Hey

Thanks, Where can you get fibreglass epoxy? Is it similiar or the same as just normal epoxy?

Thanks,
- Duncan

[decke48]

most auto parts store have it. you can buy the kit(comes with a 48x48 1ounce cloth and 32ounce of resin and hardener) or you can buy the cans of resin and hardener

[iampetro]

whats with the busted bottom tab buisiness????
i've taken my grill out many times and ever since the first time i
just use a longish flat head screw driver and reach up from where the
front plates go. the bottom tabs are upsidedown ver. of the top ones
so just push up in the middle and they slide right out. no pulling pressure
required, once there all popped it wants to come out :wink:

[warrior]

Baaaaaaaahhhhhhhhh.. someone update the pictures damnit :smt012

[Red Baron]

Heres my custom grill, took a while to get it all done, but it wasn't hard work. I'm going to put my Subaru logo back on it eventually. I plan to put black metal flake stars and a red background. I just need to figure out how to attach it.

https://sl-i.net/FORUM/images/imported/2009/09/9fr888-1.jpg
https://sl-i.net/FORUM/images/imported/2009/09/34spilv-1.jpg

[99gtlimited]

just finished doing my own, now i just need a badge...

I'll post installed pics when done

https://sl-i.net/FORUM/images/imported/2010/04/0409002121-1.jpg

[chaksq]

just finished doing my own, now i just need a badge...

I'll post installed pics when done

[img]
Your grill looks good. You should snag one of the Replica L7 badges from 02legacygt. I snagged some from him and it looks great, he shipped mad fast too.

[Soul Shinobi]

Any chance you could get the original pics back up? It'd be a great help, I'm pretty bad using body work stuff.