a little ghetto, but nonetheless great diy
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.
-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.
Fusor products used..
Used grille $40
Fusor products $35
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!!
Modified by Royale5 at 9:50 PM 12-1-2007
Modified by Royale5 at 9:57 PM 12-1-2007
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
Audi b5 wiper motor FS http://forums.vwvortex.com/showthrea...FS-Wiper-Motor
b5 avant For Sale http://forums.vwvortex.com/showthrea...7#post80441937
added to the DIY/FAQ
Current: 2011 Jeep Grand Cherokee 5.7 Hemi 4x4, 2013 BMW 650GS Sertao, BMW 1150RT
Gone: 2010 Audi S4; 2008 GTI; 2007 Audi A6; 2004 Audi allroad 2.7T; 2001 Audi A6 2.7T; 1999.5 Mk4 Jetta VR6; 1991 Jeep Cherokee 4.0 4x4
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.
As long as it works......... nice move mate!!!!
would you mind showing us the dremel bit that you used to cut that grille up?
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
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?
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.
"The hype of a wheel is not a derivative of its price... The cost is a derivative of their hype." M. Burroughs of Stanceworks