**DIY - NON Sag Badgeless Grill"E"**

[Royale5]

I saw a post earlier about an idea to solve the dreaded sagging grille dilemma. Well I had done this work over the summer using 2 stock grilles and I can guarantee it will never sag. Here is a good DIY for anyone who has experience with fillers.

Materials needed.

- Dremmel
-2 stock grilles - both from the same car (ie. 2 jettas or 2 golfs)
-Lord Fusor 143
-Lord Fusor 602 (adhesion promoter, is a must)
-Lightweight filler of your choice
-Paint (the rattle cans from perf. cafe would work great for a color match)
-Bumper and hood notch fillers

Fusor products needed are the following..
Fus 143 and Fus 602 are the materials you need. You will need the Fus 513 caulk gun conversion kit and the mixing tips are Fus 400.

http://www.autobodydepot.net/s...s=6L1

Fusor products used..

COST
Used grille $40
Fusor products $35
Filler $12
Flat Black Paint $3
TOTAL COST $90

On with the process....

1) First step is to remove the VW emblem and remove the colored "grille" piece from the backer.

Colored "grilles" removed from the backer.

2) Take the backer piece and begin to cut out the round center area where the VW was.

Black backer piece.

Center round piece cut out.... This piece will be the backer for your new grille.

3) Use the backer off the "donor" grille and cut off the area circled in red... This will be the KEY to the non sag support!

4) Take this piece and place it up to the new backer piece and trace the "notch" shape so you can trim for a nice fit... Also trim the horizontal bars to fit in the void.. **be sure to leave some room so the pieces are not jammed in there**

5) Trim the marking and test fit the piece..I used ductape to hold the pieces together for mock-up.

This picture shows the whole backer piece of the new grille, the vertical support (red arrow) is the key to this grille never sagging.

6) Now use the fusor to bond these pieces together. Make sure they are level and flush! When the fusor is set up sand clean.

7) Once the backer piece is finished you can start on the "grille" part. Same idea as the backer piece.. Remove the round VW area off the new grille. Use pieces off the "donor" grille to fill the space.

Use the fusor again to bond the pieces together.

Once sanded use the lightweight filler to smooth out. Prime, paint, and install. Don't forget to paint the notch fillers!!

Finished result..

Modified by Royale5 at 9:50 PM 12-1-2007


Modified by Royale5 at 9:57 PM 12-1-2007

[VDUBRACER187]

a little ghetto, but nonetheless great diy

[Royale5]

Quote, originally posted by VDUBRACER187 »

a little ghetto, but nonetheless great diy

Thanks but I really don't see how its ghetto, it works and looks 100x better than any badgeless grille out there.

[DJKeebler]

A lot of work for a part that you can now get for between $50-70 used but props for a nice job.

[VDUBRACER187]

now that i see the pic of it on your car i take that back...

[2Slo2Run]

omg, wow, if i decided to go badgeless and not sell the JOM i was supposed to get in the mail 2 weeks ago ( -> DubStop) oh well, i guess if i dont sell it and the JOM sags to my disliking ill try this... wonder how much a stock grill could go for in a junkyard somewhere

[abydielsgli]

[BHB]

added to the DIY/FAQ

[99VR6]

nice job! def. impressive

[pirate golf]

Quote, originally posted by Royale5 »

Thanks but I really don't see how its ghetto, it works and looks 100x better than any badgeless grille out there.

Not ghetto in the least bit. I don't know what that idiot is talking about. Sagging grilles look so retarded. It's great to see that you've come up with a solution to them. Great job on the DIY.

How much did everything cost you? This is probably a little cheaper than buying an aftermarket one that does sag.

[JettaJayGLS]

VERY NICE DIY!

[mozcar78]

As long as it works......... nice move mate!!!!

would you mind showing us the dremel bit that you used to cut that grille up?

[nothingspecial]

Hi, where do you get the fusor?

[JettaGT8V80]

good thing is that people sell thier stock grills for like $30 so really your investment is only like $70

and its 100 times better than any sagging crap you can buy

[Calitri-Boost]

sweet nice job man...

[jetta1.8tbee]

oh man, nice work

[Suubes17]

came out real nice

[Snook]

looks awsome

[platinumedVR6]

nice, gonna show this to my cousin

[RafaGolfBr]

sweet work on the bumper also (lower grille )

[vrsixt9]

not my style

[RavinJetta]

Nice job

[Chacolla]

Quote, originally posted by bhb399mm »

added to the DIY/FAQ

they made you a mod?

[greyvdub]

Quote, originally posted by Chacolla »

they made you a mod?

yeah because it works.

[monosylabik]

looks good

[CraigsVR6]

Awsome job bud!

[idwurks]

Jon you need a job as an Industrial Designer. I swear you surprise me every time you post

[VR6inAZ]

what are you people bitching about? this is a great diy, looks as good as any other aftermarket piece and like he said, no sagging.

[dansonepointeight]

wow amazing

[Eric@SETuning.com]

that is plain awesome! great DIY!

E

[dubjager]

thats a nice bit of work there. props man. it came out nice. a little to intricate for me but def. nice work

[silveratljetta]

great write up

[JTI 18t]

Quote, originally posted by vrsixt9 »

not my style

im guessing sagging is your style
not quite sure how a nonsagging grill is not your style but o well

to royale:
wow great write up!! like ^^ a little intricate for me, which i had the skills to do it, will you be selling these or is this a one time only thing?

[1goodguy]

Modified by staggered mk4 at 3:24 AM 11-8-2005

[staggered mk4]

Quote, originally posted by 1goodguy »

or you can just buy a bonrath grill for less than a hundred bucks??

or better yet, don't threadjack. It's disrespectful. I'm asking nicely.