Thread: Mesh Grill write up

Hi folks.
Just a quick write up of how I did my mesh grill on the D2, some costs involved, pointers etc. I realise there are other threads on this, however I found them to be a bit light on some info.

So, first step, open the bonnet, and remove the grill. To do this you have to undo the three screws in the top, and remove the clips they sit in. You'll also need to remove the hockey sticks from underneath the headlights, by undoing the screws in the forward face of the wheel arch. Then you can access the lower screws on each side of the grill.

Next, what I did was clip the ribs between the plastic panels, to make removal easier.



Next I cut the middle section out with a dremel tool. I didn't have one prior to this, however I found a good 200 piece kit at Jaycar for $39. Cheapo I know, but it works fine.

So after cutting out the middle section, I began to tidy up the dags left behind, as well as starting to remove some more of the surrounding plastic.
Next step was removing the slanted face from the lower panel



I taped the edge up and marked it.



I also cut it into sections to make getting a straight edge a bit easier.

So then I was left with this...





Considered leaving the bottom black panel in but decided it would look better without, so out it came.



Next, I wanted to cap the edges so it looked a bit tidier, at least along the paint edged sides as if I got too close to really tidy them up then I'd risk marking the paint, so I slit some fly screen tubing, or spline as it's called, and used that. I'd recommend getting some proper edging, as trying to sikaflex spline onto an edge was a bloody nightmare!






Next I laid the mesh on top to get an idea of where I needed to cut it, which took some back and forth work to get it correct. It's just generic auto mesh from SCA, for about $30



This is with the mesh sitting in before sikaflexing



Next, I sand papered and wire brushed the plastic, as well as giving it a thorough clean with some turps to ensure a good bond and sikaflexed it up.
I then place the mesh in, although I had put it in before to allow me to bend the edges over so they sat flat against the plastic. And by bend I mean bash with the brush handle



Let it set, put it back together and hey presto





It needs more work, there are quite a few sikaflexy fingerprints that need cleaning, and part of the top section wasn't pressed into the sikaflex enough but it's still remarkably sturdy.

A quick rundown of costs:

Mesh: $30
Dremel tool: $40
Sikaflex and caulk gun: $32
Allow $10 or so for any other odds and ends you might need if you don't already have them.

All in all, a pretty easy and cheap mod that looks much better, and hopefully better airflow.
Cheers
Muppet

Looks good. Some thing I'd do if I had cooling issues.

I might still, just for the cooling benifit.

Happy Days