How-To make Custom Sport Style Grill
This is the procedure I used to make a sport style grill for my Infiniti G20. It will work for all cars with a separate or chrome grill, but the process may vary depending on the car. This should help you get the basic idea how to go about making one for yourself.
Its a good Idea to get an extra grill before attempting this. I got mine from a junk yard on line. The first time I tried this I broke the grill because I was in a rush. So take your time!
tools and suppies
jig saw or Dremal
Body filler
Mesh screening
Before
After
The first step is to remove any mounting bolts that might be in the way of your cutting. Once everything is out of the way cut the grill to get rid of the slats and get the desired shape. Be very careful when cutting this is my second attempt the first one broke when cutting and hit the bolts. Make sure to leave some of the mounting tabs/bolt locations so you will be able to reattach it later. I didn’t like the way the grill dipped down for the emblem so I shaved it straight, but that was my personal taste and you should do what you like here. It should now look like the picture below.
Next you need to smooth the grill and shape it filling in any open areas left after the removal process, like on the top of mine. I used a small belt sander and a file to smooth the bottom and sides, but a Dremal will do the trick with the right bit. Then fill any imperfections and gaps with bodyfiller and sand till smooth. After the big stuff is filled in I like to use filler primer to get all the little scratch left from sanding.
Next step is to cut the mesh to fit the inside of the grill. Make sure to leave it a little larger so you wont see any gaps. I was able to bend it around inside the grill to keep it in place. I Cut the bottom around the bolts but left it tight so you have to force it around the tabs.
After every thing is shaped and fit I primed and painted the grill. Then I put the emblem from the trunk in the center of the grill.
And thats the process I followed to make my custom grill. I hope this helps give you an idea how to go about modifying your grill.