jonnycatbiscuit

Had a go at this about three weeks ago, and so far the opinions are all positive, so here's a brief "how to" for all you budding diy modders...

STEP 1 - remove grill from car
I won't insult you by telling you how to do this
STEP 2 - dismantle grill
again, straightforward - it's in three pieces, slats, inner ring and outer ring. Most of it snaps apart by applying light pressure to the clips whilst pulling gently
Step 3 - discard slats, you should be left with this inner ring/grill


STEP 4 - remove Skoda badge - it's just stuck on with two plastic rivets on the back. grind or drill these out...



STEP 5 - using a hacksaw or dremel, cut across the top of the greill as shown, leaving a straight edge. Best to cut off less than you need 'cos you can always sand back, but adding material on is harder...


STEP 6 - using card and masking tape, fashion an "edge" to the cut part - to give the fibreglass matting something to form to



STEP 7 - from behind the grill, reinforce with fibreglass matting and resin. plenty of small sheets rather than one or two big ones, for extra strength


STEP 8 - once the fibreglass is dry, remove the tape and card, sand back to get a smooth edge, and apply bodyfiller to the crescent shape indent left by the top of the skoda badge
(sorry, forgot to take a pic of this stage)

STEP 9 - sand back the filler and paint. Remember, the more time you spend getting the finish absolutely flat, the better your finish will be. (Mine was a bit rushed, as I needed the car back on the road


Mesh application to follow. Got to go and get ready to go out...

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jonnycatbiscuit

Step 10 - cut the inner edge of the inner grill down by about 1mm (the edge indicated by the arrow). This is because the inner and outer grills overlap and there isn't enough space to accommodate the mesh unless you trim one or the other.


I used a dremel with a tiny cutting disc, but you could equally use a stanley knife if you have thick gloves/strong fingers...

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Babs

OT but I have the same worktop in my kitchen

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jonnycatbiscuit

Step 11 - cut the mesh to size, overlapping the inner grill by about 5mm or so. Bend it carefully around the inner edge of the grill, and stick it in place with sikafelx or something equally sticky.


and from the front, once stuck


Step 12 - paint the mesh and grill again, and refit.
Simple


opinions/questions welcome....

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speednut

Better than my lame attempt to explain, exactly how I did it except Ileft the badge on. Top job

Steve

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Jabbasport IHI VF34 turbo conversion/CAI/FMIC/Exhaust manifold/Boost controller 277bhp-337bhp,3" Blueflame downpipe and 100CEL Sports Cat,Cobra custom made cat back by Exhausts UK,Audi S3 MAF,Audi S3 ASR,Bailey DV30 diverter valve,KW V3 Suspension, Mintex brake discs,Ferodo DS2500 pads,Matt black OEM alloys,Neuspeed ARB,Audi S3 upper/lower strut brace,Prospeed Motorsport WRC spoiler,Sachs clutch,Cruise control, G ,,Milotec bonnet lifters,Carbon front splitter, Full tints Dark Smoke rear+ Light Smoke fronts New badge ,modded grille

Ender

Top how to mate!,

but what paint did you use and where did you get it?, also does just paint str8 onto the plastic?

cheers in advance

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Mods-
ABD racing CAI --- ABD racing TIP --- Forge DV --- Blue flame full sytem --- Koni FSD's --- Bosch aero twins --- Fuel 4 5 Stud - 18" --- Milotek 3 grill set --- Milotek bonnet lifters --- Eibach springs --- Impossible Performance custom remap

'Impossible' is Nothing

dakar

Looks good

craig0031

how do you open your bonnet now though :o i thought you had to cut a hole out for the lever?

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warwick hunt

bonnet is welded shut..all work done from below.

speednut

:

Sorry could not resist

Steve

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Jabbasport IHI VF34 turbo conversion/CAI/FMIC/Exhaust manifold/Boost controller 277bhp-337bhp,3" Blueflame downpipe and 100CEL Sports Cat,Cobra custom made cat back by Exhausts UK,Audi S3 MAF,Audi S3 ASR,Bailey DV30 diverter valve,KW V3 Suspension, Mintex brake discs,Ferodo DS2500 pads,Matt black OEM alloys,Neuspeed ARB,Audi S3 upper/lower strut brace,Prospeed Motorsport WRC spoiler,Sachs clutch,Cruise control, G ,,Milotec bonnet lifters,Carbon front splitter, Full tints Dark Smoke rear+ Light Smoke fronts New badge ,modded grille

claytarget_god

thats a good question actually mate, havent you got rid of the grill bit?

that is the strength to the hole thing, I have done mine and i cut the front bit out then put the mesh in and moulded it into shape so it is slightly rounded then clipped it all together again, all I had to do was glue the silver bit back in and glued the mesh round the edges, but mine still has the strength, have you done the same?

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Done: PowerFlex Dogbone Bushes,Forge FMIC,CAI,forge DV, Longlife 200cel Cat 2.5" cat-back,Weitec GT coilovers,Whiteline 22mm ARB and S3 Front Lower Brace,SuperPRO Wishbone/Front ARB Bushes,Remap,LCR Front Splitter, Milotec front grills,EBC grooved/dimpled Discs,Black Diamond Predator Pads,18" Team Dynamic Pro Race 1.2(StarSilver) To Do: TIP,Tinted Windows, Front Bumper: Milotec Side Vents,Milotec Rear Bumper Splitter, RSTuning Custom Remap.