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    Thread: DIY: Badgeless Aero Grille (56K go clay bar your ENTIRE car)

    1. 05-14-2006 12:13 AM #1
      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.


    2. 05-14-2006 12:16 AM #2
      very nice DIY

    3. Member Gans's Avatar
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      05-14-2006 12:18 AM #3
      good write-up!

    4. 05-14-2006 12:20 AM #4
      is that the poor mans badgeless grill. hehe nice job buddie.

    5. Member Bondoboy's Avatar
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      05-14-2006 12:23 AM #5
      good job

    6. 05-14-2006 12:24 AM #6
      Quote, originally posted by HomeSlice989 »
      is that the poor mans badgeless grill. hehe nice job buddie.
      ]

      Damn straight it's the poorman's grille!

      Thanks for the positive comments


    7. Member SetStatic's Avatar
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      05-14-2006 12:26 AM #7
      Nice write up...this may give me a reason to actually do something with the stockpile of areo grilles I've got collecting dust
      CBS

      :snore:

    8. Banned knappy's Avatar
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      05-14-2006 12:27 AM #8
      This should go into the FAQ's. IM The_Hamster and have him add it. Good write up.

    9. 05-14-2006 12:39 AM #9

    10. Member PDXGTI8V 2.0's Avatar
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      05-14-2006 01:14 AM #10
      Nice write up

      why didnt you color match your upper grill spoiler while you had it off the car??...if you had done that, your front end would truly be "done"

      My 91 GTI 8V, original owner stylz, yo!: http://smg.photobucket.com/user/pdxg...%20july%202013

    11. 05-14-2006 02:16 AM #11
      awsome!!

      now I just need to get 2 aero grilles to do the DIY.

      ps. has anyone done the older style golf/jetta grill to make it badgeless??
      thanks


    12. Member cmoneyg60's Avatar
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      05-14-2006 02:19 AM #12
      way to go. looks good and its a good money saver

    13. Banned PDXDubLove's Avatar
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      05-14-2006 02:27 AM #13
      Quote, originally posted by dlin15 »
      awsome!!

      now I just need to get 2 aero grilles to do the DIY.

      ps. has anyone done the older style golf/jetta grill to make it badgeless??
      thanks

      ive considered doing that, i think the old 7 slat would look pretty neat.


    14. 05-14-2006 02:34 AM #14
      7 slats would be cool, if you could find 2 of them in the amount of time you have patenice for it.


      I have done this to my grille, I have no critisizim except that i kept the very top part of the grille thats not one of the bars.

      kept it sturdier in my mind. ( also less work.)


      Thumbs up for the write up.


    15. Member morimori's Avatar
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      05-14-2006 10:45 AM #15
      good diy

    16. Member Jezztor's Avatar
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      05-14-2006 10:47 AM #16
      Good job, as knappy said, make sure you get this put in the DIY thread.

    17. Banned indianakar's Avatar
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      05-14-2006 11:00 AM #17
      NICE!!!!!!!!!!!

      I have a spare grille, I'll do this on monday!


    18. 05-14-2006 11:38 AM #18
      Great write up.
      [B][URL="http://jminorphotography.com/"]My Landscape Photography website
      Google+

    19. 05-14-2006 11:52 AM #19
      Yeah man, good write up.

      I keep meaning to do a badgeless 7Slat grille...

      "DIY: Badgeless Aero Grille (56K go clay bar your ENTIRE car)" Lol'd at the title too!


    20. Banned cbacon411's Avatar
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      05-14-2006 01:08 PM #20
      yea nice write up, thanks to you im going to try this once i get some free time. thanks a lot

    21. 05-14-2006 02:12 PM #21
      came out real good

    22. Member Black86GTI's Avatar
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      05-14-2006 06:38 PM #22
      Quote, originally posted by mk2jettarunner »
      7 slats would be cool, if you could find 2 of them in the amount of time you have patenice for it.


      im starting my badge less 7 slat tommorow ill take pictures


    23. 05-14-2006 06:56 PM #23
      I usually Plastic weld these together, only difference other than that is I leave the top edge of the grill intact to help keep it's integrity.

    24. 05-14-2006 07:58 PM #24
      Quote, originally posted by Ische »
      I usually Plastic weld these together, only difference other than that is I leave the top edge of the grill intact to help keep it's integrity.

      I usually plastic weld too. But this was my first time doing this, and it holds up very well with the epoxy. Thats also why it didn't matter about the top part of the grille, because the epoxy holds it steady. Also I use a grille spoiler, so that kind of holds it together in a way as well.


    25. 05-14-2006 07:59 PM #25
      Quote, originally posted by PDXGTI8V 2.0 »
      Nice write up

      why didnt you color match your upper grill spoiler while you had it off the car??...if you had done that, your front end would truly be "done"

      For some reason I like the grille spoiler textured.


    26. 05-15-2006 11:42 AM #26
      cool i might go do mine soon and can you show us pics of what you used to make the grile

    27. Member TMH's Avatar
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      05-15-2006 01:54 PM #27
      Quote Originally Posted by Chris Stack View Post
      I often pass slow-moving Priuii on the right, my engine clubbing 9000 baby seals per minute while I do so.

    28. 05-15-2006 02:00 PM #28
      Good stuff

    29. Member Black86GTI's Avatar
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      05-15-2006 05:31 PM #29
      hmm not gonna steal this guys thread but i used about the same procedure just on a 7 slat grill. so i thought i would show you guys a partialy completed picture of the 7 slat badge less


    30. 05-16-2006 08:20 AM #30

    31. 05-16-2006 09:05 AM #31
      If anyone wants me to fab one of these up for them, shoot me an IM and we can work something out

    32. Member Black86GTI's Avatar
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      05-17-2006 01:01 AM #32

      badgeless 7 slat is lots of time to get right but i like how its coming out. and the fitment of home made badge less grills is top notch compared to FK or any of the other makers.


    33. 05-17-2006 11:26 AM #33
      Quote, originally posted by Black86GTI »
      badgeless 7 slat is lots of time to get right but i like how its coming out. and the fitment of home made badge less grills is top notch compared to FK or any of the other makers.

      Great job on the 7 slat grille...personally I like the 3 bar better though. You are right about the fitment, the homemade badgelesses fit pretty much perfectly


    34. Member Black86GTI's Avatar
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      05-17-2006 01:50 PM #34
      Quote, originally posted by dinamikworld »

      Great job on the 7 slat grille...personally I like the 3 bar better though. You are right about the fitment, the homemade badgelesses fit pretty much perfectly

      the only real reason i did the 7 slat was becuase it was more common on small bumper cars and my car is small bumper, small door, so it kinda fits the style of the car. i would have done a 3 slat if i could have found the grills i needed.


    35. 05-17-2006 07:36 PM #35
      If anyone in here is looking for "core" grilles to modify, I've got two, old and new, both oem. IM me for details

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