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Old November 26th, 2003, 10:16 PM   #1
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HOW TO: DIY Grille for the 98-00 Coupe

Ok, I’ve looked all over the forums and I have not found a DIY for this. People have requested it so ill post it.

What you need:
• Hack Saw blade or a dremmel tool or something to cut
• Duck Tape
• Fiberglass mat
• Body filler or Bondo and hardener putties
• Body Putty
• Popsicle sticks or something to spread the bondo evenly
• Rough sand paper (like 220 grit) and Very fine sand paper (like 1000 grit)
• X-acto knife (not a must)

You can find all this at Pep-boys or something like that; Wal-mart has a lot of it.

First Step-

You have to take out the Grille (you can go to the DIY black out headlights to learn how to take off the bumper) There are 3 or 4 screws at the bottom of the grille once you take off the bumper. Take those out, along the three clips on top of the grille and it’ll slide out.
Now you need to cut out the center section. You will need a hack saw blade or something small to cut this out. Cut along the bottom of the inside of the grille to get center out. You’ll figure it out. Heres a pic of where you should cut.



Step two-

Now that you have the center out, you will have 2 holes on the side and a gap in the middle. You will also have some bumps from those little tabs in the middle. Try to smooth or cut those holes and bumps down to the same level as the surrounding area with a dremmel or the same thing you used to cut out the center.

Step three-

Ok now for the fun part. People have a few different ways of doing this so there might be easier ways that I don’t know about or haven’t tried.

You will need to back the holes in the grille with duck tape or something that will let the Bondo stay on one spot. You can back these holes up with some fiberglass matting
Now that you have backed up the holes, its time for the bondo. There are directions on the package that shows you how to mix it, but if you are mixing a small amount of it make sure that you don’t use too much hardener or it’ll dry pretty fast.
Get a glob of the bondo a put it on the holes. Smooth it down so you wont have to do as much sanding/cutting.

Step four-

Time for sanding. If your bondo is piled high, you can use an x-acto knife to shape it. Now that you have done that, use your rough sand paper and just sand your heart out. Try to sand as smooth and even as the area around it.
Once you have done this, there will probably be some holes and other ugly spots you can’t sand out. You can use the putty to fill in the holes/spots. Wait for the putty to dry and sand it down with sandpaper again.
Now that you have the holes filled in, you can use fine sand paper. I wet sanded all of the spots and got a real smooth finish.


This is not the easiest thing to do, and I will not be held responsible for what happens. If you mess up, just break or sand off the bondo and start over. If I missed some steps PM me or reply and ill add them. its been a long and tiring day and i couldnt sleep so i posted this, so more than likely i missed some steps

Here are some pics of the finished product and some of the process.













Im not finished painting it, but thats what i have right now for the time being.
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Last edited by Comptechjunkie; December 2nd, 2003 at 06:19 PM..
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Old November 26th, 2003, 10:26 PM   #2
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Nice! Can't wait to see the finished pics.
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Old November 26th, 2003, 11:10 PM   #3
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Very nice!! I think i might try that with my old grille/.
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Old November 27th, 2003, 12:22 AM   #4
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damn, that just seems like wayy too much work

the 5th gen accords and 6th gen civics have it easier, the outer peice of the grillle is just screwed on! so you can attach mesh to it and attach it back on

i just attached some mesh to my bumper with some ties, looks good and its time and cost effective!
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Old November 27th, 2003, 07:42 AM   #5
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you dont have to take off your bumper, but its hard to screw the screws back in wit the bumper on
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Last edited by Comptechjunkie; November 27th, 2003 at 05:11 PM..
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Old December 5th, 2003, 12:31 AM   #6
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Which place can we buy those aluminum screens or mesh screens. Is there a place that we could buy this thing with different variety such as honeycomb mesh screen.
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Old December 5th, 2003, 06:08 PM   #7
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Home Depot have a 3'x8' screen like that for $3 near the tar for roofing.
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Old December 5th, 2003, 10:45 PM   #8
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better known as gutter guard
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Old December 6th, 2003, 12:36 AM   #9
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Quote:
Originally posted by Comptechjunkie on December 5th, 2003 at 11:45 PM

better known as gutter guard
naw the gutter guard stuff that comes in a roll sux, its so small and too loose, it bends real easy, i had that at first, and got rid of it

I used a sheet for my current grille, really tough **** which is pretty damn hard to bend, I got it from a stucco guy who used it to bend around a pole to hold the cement before he stuccos it.
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Old December 6th, 2003, 08:39 PM   #10
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got a pic?
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Old December 14th, 2003, 03:25 PM   #11
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looks good.. why not just buy the type r one on procar parts for 40$ for the same effect? -Jai
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Old December 14th, 2003, 03:49 PM   #12
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are the grilles from procarparts.com black?
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Old December 14th, 2003, 04:53 PM   #13
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Quote:
Originally posted by Comptechjunkie on December 6th, 2003 at 09:39 PM

got a pic?
I'll try to take some pics soon
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Old December 14th, 2003, 09:55 PM   #14
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Quote:
Originally posted by 98vtech
are the grilles from procarparts.com black?
yes.
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Old December 15th, 2003, 01:45 PM   #15
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When I still had my stock bumper I did the same thing but I fiberglassed the sides that got cut off, sanded it all down and bondo'd over it. It makes sure the bondo doesn't get all jacked up when it flexes because hand-laid fiberglass sheets fills in gaps better.

Anyway, yours looks absolutely gorgeous! $40 well saved (not to mention it fits like OEM - because it is!)
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Old January 13th, 2004, 02:41 PM   #16
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i just did a grill for a guy and i used fiberglass and then bondo then teh putty and it flexed without cracking, so i also recomend using fiberglass too
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Old February 17th, 2004, 08:26 PM   #17
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i will never attempt this DIY again...but it was well worth it
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Old February 17th, 2004, 08:40 PM   #18
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yeah im using Bondo brand fiberglass kit as we speak, and my step dad is bringing me some kind of putty tomorrow. the fiberglass is defintiley hardening, but being that it was my first time, the surface is not as as smooth as i want it to be.
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Old February 19th, 2004, 12:02 AM   #19
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I used a much easier method to make a custom grille. Using a sheet of mesh from APC which cost me $25 i first made a cardboard template. Then i cut out the mesh which was real easy only needed normal scissors and bent the top over the bar where the OEM grill clips in on top. Two screws with washers drilled into that bar keep the mesh well anchored and could easily be anchored on the bottom by drilling some holes and using zip ties. I'll have pics of it soon. It only took me about 20 minutes to do and i am very pleased with the results except i ****ed up one of the corners, oh well.
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Old February 19th, 2004, 12:45 AM   #20
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I had done kind of the same thing but with hard mesh

pic


http://www.imagestation.com/picture/...7/f9e9931a.jpg

http://www.imagestation.com/picture/...f/f9e9939c.jpg

the bottom isnt attached in the pics which is why its sticking out on the sides

anyone want them, i still have them for sale
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Old February 26th, 2004, 06:50 PM   #21
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where can you get this fiberglass stuff whats it called?
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Old February 20th, 2005, 02:11 PM   #22
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Quote:
Originally Posted by HIREN
I had done kind of the same thing but with hard mesh

pic


is that a sedan you cleared the grille out of?
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Old February 20th, 2005, 06:36 PM   #23
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It's a coupe.

BTW, a year later they're still for sale! I have them sitting in storage.
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Old February 21st, 2005, 05:13 PM   #24
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wow this is weird... i was looking at the date and i thought that the posts were like last week, but it was last year lol thats funny
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