Ok, if there is already a DIY for this, someone delete this post. But I figured I should try to make a semi-decent writeup on a badgeless aero grille since I know many people are like me, and dont want to spend the money on one.
To do this project, you will need 2 aero grilles, a tube of good epoxy (i used the quick set loctite stuff), 400 and 600 grit sandpaper, a hacksaw with a nice, sharp blade, and a tube of plastic filler.
The pics may not be the greatest, but I tried.
To begin, lay both of your grilles side by side, to see where you will begin cutting.
I decided to cut a 8 1/4" section from the grille I was going to use as the badgeless. This was the badged section I removed.
After I had the section removed, I layed that portion ontop of a "blank" section on the other grille. I then cut out a section the same size, to fit into the other grille.
Once you have the "blank" section removed, feather the edges that you cut with some sandpaper or a coarse file. Do the same to the grille you will be using. Then, do a test fit, and adjust what you don't like.
Now it's time to mix up some epoxy. Spread it on both mating surfaces, then place the blank section into the grille, position it, and let it dry THOROUGHLY...or it WILL crack.
After the epoxy is fully set and ready to go, start sanding. Make sure everything is level, and there aren't any rising or dipping sections. If there are any visible seams left, use some plastic filler on them, and sand it down again. Sand with 400 first, then 600.
When you're done sanding, wash the grille up real well with some water, and let it dry. Then spray a coat of whatever paint you want on it...I used rust oleum gloss black plastic paint.
Lastly, put the grille on your car, have a and feel good that you saved alot of cash.
IM me if you have questions, im glad to help anyone with this.